drivecon xt series owner’s manualservice 21 . owner's manual drivecon toll free ph: 1-800-374-8266...

Owner's Manual

Drivecon Toll Free Ph: 1-800-374-8266Drivecon reserves the right to alter or amend the above information without notice

Owner’s Manual

Drivecon XT Series Owner’s Manual

820 Lakeside Drive - Gurnee, IL 60031

Phone: (847) 855-9150 Fax: (847) 855-9650 1-800-DRIVCON (374-8266)

www.drivecon.com Email: [email protected]

Revision 5.4D Pro1V050 6-01-04

Owner's Manual


Table of Contents

CHAPTER A - SAFETY Forward A-1 Examination before installation and Purchase History A-2 Safety Precautions A-3 Understanding and selecting the correct part number A-7 CHAPTER B - TECHNICAL DATA Introduction B-1 Technical Data B-2 CHAPTER C - INSTALLATION INSTRUCTIONS Installation instructions C-1 Stripping length of motor and main cables C-2 Cooling C-3 Inverter Dimensions C-5 CHAPTER D - WIRING AND SIZING INFORMATION Cable installation and the UL standards D-1 Cable and Motor insulation checks D-1 Cable and Fuse sizing D-2 Frame sizes and installation of cables D-3 Control unit D-7 I/O and Relay Boards D-8 Digital Input Connections D-13 XTD-4000 Series Open Loop Traverse Wiring Diagram D-14 XTD-4000 Series Closed Loop Traverse Wiring Diagram D-15 XTD-4000 Series Open Loop Load Brake Hoist Wiring Diagram D-16 XTD-4000 Series Closed Loop Hoist Wiring Diagram D-17 CHAPTER 1 - DESCRIPTION Functional Discription 1 Control Methods 2-3 Mechanical Brake Control 4 Motor Control Modes 5 EMC 6 CHAPTER 2 – START-UP PROCEDURE Checks 7 Test Run 8 CHAPTER 3 – PARAMETER ADJUSTMENTS Control Keypad 9-10 Monitoring 11 Parameter Groups 12 CHAPTER 4 – COMPONENTS Spare Parts List 13 Spare Parts List 14 Fault Codes 15-19 Fault Counter 20 CHAPTER 5 – SERVICE Service 21

Owner's Manual


CHAPTER A – SAFETY

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, contact your local distributor or Drivecon at 1-800-374-8266 toll free or 847- 855-9150.

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 thecomponents and signals on the PCB while the inverter is running or power is on.

• Do not 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

orNEC 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.

CAUTION 1. Before starting, read carefully instructions. 2. Verify all connections are according to drawings. 3. Verify motor supply is connected correctly, wrong connection will destroy the inverter. 4. Check device cover is properly installed. 5. High voltages are present in this device. Switch power off and after display turns off, wait 5

minutes before opening the cover. 6. Insulation resistance test with a megger requires special precautions. 7. Do not make any measurements inside the device when it is connected to main supply. 8. Do not touch the components on the circuit boards. Static voltage discharge may destroy the

IC-circuits. 9. Check all ventilation holes are clear and uncovered.

10. Check that hot air coming from brake resistors does not cause any damage to surroundings. 11. Do not make any inspections unless the supply has been disconnected by main switch. 12. It is forbidden to use portable phones near this device with the doors open. 13. All the doors and covers must be closed when crane is in operation.

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Owner's Manual


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 Drivecon if you find any abnormal conditions as mentioned above.

Caution!

Failure to inspect the inverter may lead to damage of the system and possible down time. Should you find any reason to suspect the unit itself or any part of the system to be faulty please contact Drivecon toll 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: _______________________ WARRANTY Seller 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 for 24 months following the date of shipment. Seller is the sole determinant of all claims under warranty, is not responsible, and will not issue credit for defects and damage that arise from improper installation, neglect, improper use, unauthorized repairs or alterations, or from normal wear and tear.

During the warranty period, Seller will repair or replace, FOB its plant, any parts reported and found to be defective by its inspection. Seller will not assume any expenses or liability for any work done on its equipment outside its plant without its written consent, and such unauthorized work will automatically void Seller’s warranty.

Field labor and any related expenses are not covered under this warranty. A purchase order is required for any and all field work.

This warranty is in lieu of all other warranties expressed or implied, including warranty of mer-chantability of fitness for a particular use.

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Owner's Manual


Safety Precautions 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!

• The input power source must be connected to main input power terminals L1, L2, and L3.

• 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 output terminals 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 near 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 50°C to avoid overheating.

• Turn off the power supply before removal or installation of the 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 confirm the operating range of motor and machinery with respective manufacturers.

• Do not examine the signals on the PCB of the inverter while it is operating. • All inverters have been adjusted properly at the factory. If adjustment is required

consult the manual and do not exceed normal operating values. • Do not disassemble or examine the inverter before ensuring that the power is off

and the charge indicator has been extinguished. • Insure that all safety devices on the machine are operating correctly such as: limit

switches, brakes, etc.

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Owner's Manual


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 the motor ON with a contactor connected to the inverter's output while the 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 an 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

confirm 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.

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Owner's Manual


During examination and maintenance

CAUTION!

• Inverter environment should be within the following specifications: 0°C - 50°C for inverters located inside cabinet. -10°C - 40°C for inverters located outside cabinet. 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 we suggest inspection of the inverter paying 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 inverter 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.

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Owner's Manual


Operating Environment Considerations

• 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 electro-magnetic interference or ultra-high frequency

energy sources. (such as arc welders or other similar machinery) • Keep away from radioactive materials or environments • Keep away from flammable material • Keep surrounding area between -10 ~ +40°C. Installation sit conditions will directly influence the service life of the inverter. Please provide a suitable location.

Indoor mounting: 0°C - 50°C Humidity should be under 95% RH non-condensing.

Outdoor mounting: -10°C - 40°C for inverters located outside cabinet. Humidity should be under 95% RH non-condensing.

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Understanding and selecting the correct part number

In order to specify the correct part number to suit your needs please refer to the type code shown below.

XT d 4 009 0 xx V

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Owner's Manual


Chapter B - TECHNICAL DATA

Introduction

Figure 2-1 represents the block diagram of the inverter. The inverter mechanically consists of two units, the Power Unit and the Control Unit.

The three-phase AC line inductor (1) at the mains together with the DC bus capacitor (2) form an LC-filter, which, together with the diode bridge (4) produce the DC-voltage supply to the IGBT Inverter Bridge (3) block. The AC line inductor also functions as a filter against High Frequency disturbances from the mains as well as against those caused by the IGBT inverter to the mains. It improves the form factor of the DC bus input to the IGBT inverter section. The entire power drawn by the inverter from the mains is active power. The IGBT Inverter Bridge produces a symmetrical, 3-phase PWM AC-voltage to the motor.

The Motor and Application Control Block is microprocessor based. The microprocessor controls the motor based on the information it receives from internal sensors, parameter settings, control I/O and control keypad. The motor and application control block controls the motor control ASIC which, in turn, calculates the IGBT switching patterns. Gate driver circuitry amplifies these signals for driving the IGBT inverter bridge.

Figure B-1 B-1

Owner's Manual


GENERAL - Technical data Power class 4004 4005 4009 4012 4016 4022 4031 4038 4045 4061 4072 4087 4105 4140 4168 4210

Horsepower 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 Output capacity (kVA) at 460V

4.3 4.3 7.2 9.6 12.7 17.5 24.7 30.3 35.9 48.6 57.4 69.3 83.7 111.5 133.9 170

Nominal continuous output current In (A)

4 5.4 9 12 16 22 31 38 45 61 72 87 105 140 168 210

Max. current 1min (A) 10 10 15 20 27 36 48 63 72 90 113 135 165 225 270 315

Overloadability 1.5 x In , 1min/10min / 2.5 x In , 2s/20s (

Owner's Manual


Chapter C - INSTALLATION INSTRUCTIONS

1) Before installation, check that none of the components of the inverter is live.

2) If the inverter is installed outside a switchgear, enclosure or electrical room, it must be equipped with a protective cover as provided by the regulations for IP21 protection class. For installations in a switchgear, enclosure or electrical room, the cable protection plate is normally not necessary.

3) Route the motor cables clear of other cables: • Avoid placing the motor cables in long parallel lines close to other cables • If the motor cables run in parallel with other cables, note the minimum distances

between the motor cables and other cables given in table below. • The given distances also apply between the motor cables and signal cables of other

systems. • The maximum length of the motor cables is 990 ft. on all units. • The motor cables should cross other cables at an angle of 90 degrees. 4) If cable insulation checks are needed, see Chapter D.

5) Connect the cables: • Strip the motor and mains cables as shown in Table 3-2 and Figure 3-2. • Remove the screws of the cable protection plate. • Make holes into and pass the cables through the rubber grommets on the bottom of

the power unit. • Connect the mains, motor and control cables into their respective terminals. • For Information on cable installation according to UL regulations see Chapter D • Make sure that the control cable wires do not come in contact with the electronic

components of the unit. • If an external brake resistor is used, connect its cable to the appropriate terminal. • Check the connection of the ground cable to the motor and the inverter terminals

marked with ground symbol. • If shielded power cables are used, connect the separate shield of the power cable

to the ground terminals of the motor and enclosure ground terminal. • Attach the cable protection plate with the screws. • Ensure that none of the wiring is trapped between the frame and the protection

plate.

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Owner's Manual

Drivecon Toll Free Ph: 1-800-374-8266Drivecon, reserves the right to alter or amend the above information without notice

Stripping lengths of motor and main cables

Typical for shielded cables and conventional individual stranded conductors.

Figure C-2

Inverter type XTd-

Frame size

Cable striipping length - inches

or XTe A1 B1 C1 D1 A2 B2 C2 D2

4004 1 .59 1.38 .39 .79 .28 1.97 .28 1.38

4005 1 .59 1.38 .39 .79 .28 1.97 .28 1.38

4009 1 .59 1.38 .39 .79 .28 1.97 .28 1.38

4012 1 .59 1.38 .39 .79 .28 1.97 .28 1.38

4016 2 .79 1.57 .39 1.18 .79 2.36 .39 1.57

4022 2 .79 1.57 .39 1.18 .79 2.36 .39 1.57

4031 3 .79 1.57 .39 1.18 .79 2.36 .39 1.57

4038 3 .79 3.54 .59 2.36 .79 3.54 .59 2.36

4045 3 .79 3.54 .59 2.36 .79 3.54 .59 2.36

4061 4 .79 3.54 .59 2.36 .79 3.54 .59 2.36

4072 4 .98 4.72 .98 4.72 .98 4.72 .98 4.72

4087 4 .98 4.72 .98 4.72 .98 4.72 .98 4.72

4105 5 .98 4.72 .98 4.72 .98 4.72 .98 4.72

4140 5 .91 9.45 .91 9.45 .91 9.45 .91 9.45

4168 5 1.10 9.45 1.10 9.45 1.10 9.45 1.10 9.45

4210 6 1.10 9.45 1.10 9.45 1.10 9.45 1.10 9.45

Table C-2 C-2

Owner's Manual


Cooling

Enough free space shall be left around the inverter to ensure sufficient air circulation and cooling. You will find the required dimensions for free space in the table below. If several units are mounted above each other the required free space equals space B + space C (see figure on next page). Moreover, the outlet air used for cooling by the lower unit must be directed away from the inlet air to be used by the upper unit.

Dimensions - inches (mm)

Cooling air

required FT3/min (CFM) Inverter type

XTdor XTe- Frame size

A

Distance from one

inverter to the next

B C

4004 1 .787 (20) .394 (10) 3.94 (100) 1.97 (50) 41.20

4005 1 .787 (20) .394 (10) 3.94 (100) 1.97 (50) 41.20

4009 1 .787 (20) .394 (10) 3.94 (100) 1.97 (50) 41.20

4012 1 .787 (20) .394 (10) 3.94 (100) 1.97 (50) 41.20

4016 2 .787 (20) .394 (10) 4.72 (120) 2.36 (60) 111.83

4022 2 .787 (20) .394 (10) 4.72 (120) 2.36 (60) 111.83

4031 3 .787 (20) .394 (10) 4.72 (120) 2.36 (60) 111.83

4038 3 1.18 (30) .394 (10) 6.29 (160) 3.15 (80) 250.15

4045 3 1.18 (30) .394 (10) 6.29 (160) 3.15 (80) 250.15

4061 3 1.18 (30) .394 (10) 6.29 (160) 3.15 (80) 250.15

4072 4 1.18 (30) .394 (10) 6.29 (160) 3.15 (80) 250.15

4087 4 2.95 (75) 2.95 (75) 11.81 (300) 3.94 (100) 250.15

4105 4 2.95 (75) 2.95 (75) 11.81 (300) 3.94 (100) 250.15

4140 5 2.95 (75) 2.95 (75) 11.81 (300) 3.94 (100) 382.58

4168 5 2.95 (75) 2.95 (75) 11.81 (300) 3.94 (100) 382.58

4210 6 2.95 (75) 2.95 (75) 11.81 (300) 3.94 (100) 450.00

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Owner's Manual


Installation

The inverter should be mounted vertically on the wall or on the subpanel of an enclosure. Enough space shall be reserved around the inverter in order to ensure sufficient cooling, see diagram below. Also see to that the mounting plane is flat. The inverter shall be fixed with four screws (or bolts, depending on the unit size).

Installation space diagram shown at left. Dotted line represents perimeter distance around inverter. Refer to Table 3-5, 3-6, and 3-7 for mounting hole dimensions.

Hardware Instructions and Installation

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 +55°C chassis mount

• Avoid water dripping or humid environment • Avoid direct sunlight • Avoid oily atmospheres • Avoid corrosive liquid or gas • Prevent foreign dusts or metal scraps from entering interior • Keep away from radioactive or flammable material • Avoid electromagnetic interference (arc welding or power machinery) • Avoid vibration. If vibration can not be avoided, shock mounts 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. • 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. C-4

A

inverter

A

B

C

A

Owner's Manual


Inverter dimensions. Frame size 1, 2, and 3.

Table C-5

Model Number XTD-

Frame size

H1 (inches)

H2 (inches)

W1 (inches)

W2 (inches)

D1 (inches)

Hole diameter (inches)

Weight (lbs.)

4004-000 1 12.874 12.323 5.039 3.937 7.480 0.276 13.40

4005-000 1 12.874 12.323 5.039 3.937 7.480 0.276 13.40

4009-000 1 12.874 12.323 5.039 3.937 7.480 0.276 13.40

4012-000 1 12.874 12.323 5.039 3.937 7.480 0.276 13.40

4016-000 2 16.496 15.984 5.669 3.937 8.425 0.276 21.70

4022-000 2 16.496 15.984 5.669 3.937 8.425 0.276 21.70

4031-000 3 21.969 21.299 7.677 5.827 9.331 0.354 49.56

4038-000 3 21.969 21.299 7.677 5.827 9.331 0.354 49.56

4045-000 3 21.969 21.299 7.677 5.827 9.331 0.354 49.56

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Owner's Manual


Inverter dimensions. Frame size 4.

Table C-6

Model Number XTD-

Frame size

H1 (inches)

H2 (inches)

W1 (inches)

W2 (inches)

D1 (inches)


Weight (lbs.)

4061-000 4 24.803 24.173 9.331 7.480 10.118 0.354 93.77

4072-000 4 24.803 24.173 9.331 7.480 10.118 0.354 93.77

4087-000 4 24.803 24.173 9.331 7.480 10.118 0.354 93.77

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Owner's Manual


Inverter dimensions. Frame size 5.

Table C-7

Model Number XTD-

Frame size

H1 (inches)

H2 (inches)

W1 (inches)

W2 (inches)

D1 (inches)


Weight (lbs.)

4105-000 5 29.331 28.386 11.220 10.039 11.339 0.354 155.38

4140-000 5 29.331 28.386 11.220 10.039 11.339 0.354 155.38

4168-000 5 29.331 28.386 11.220 10.039 11.339 0.354 155.38

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Owner's Manual


Inverter dimensions. Frame size 6. Table C-8

Model Number XTD-

Frame size

H1 (inches)

H2 (inches)

W1 (inches)

W2 (inches) D1 (inches)


Weight (lbs.)

4210-000 6 53.149 16.54 20.86 7.87 14.251 0.354 264.55

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Owner's Manual


Chapter D - WIRING AND SIZING INFORMATION

Cable installation and the UL standards

To meet the UL (Underwriters Laboratories) regulations, a UL-approved copper cable with a minimum heat-resistance of +60-75C must be used.

The tightening torques of the terminals are given in table below.

Tightening torques of terminals * Tightening torque of terminal connection to the isolative base in Nm/in-lbs.

XT inverter type Frame Tightening torque[Nm] Tightening torque in-lbs. 4004~4012 1 0.5—0.6 4—5 4016~4022 2 1.2—1.5 10—13 4031~4045 3 4 35 4061~4087 4 10 85 4105~4140 5 20 170 4168 5 40 340 4210 6 50 425 Cable and motor insulation checks

1. Motor cable insulation checks Disconnect the motor cable from terminals U, V and W of the inverter and from the motor. Measure the insulation resistance of the motor cable between each phase conductor as well as between each phase conductor and the ground. The insulation resistance must be >1M ohm.

2. Mains cable insulation checks

Disconnect the mains cable from terminals L1, L2 and L3 of the frequency converter and from the mains. Measure the insulation resistance of the mains cable between each phase conductor as well as between each phase conductor and the ground. The insulation resistance must be >1M ohm.

3. Motor insulation checks

Disconnect the motor cable from the motor in the motor connection box. Measure the insulation resistance of each motor winding and ground. The measurement voltage must equal to at least the motor nominal voltage but not exceed 1000 V. The insulation resistance must be >1M ohm.

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Owner's Manual


Cable and Fuse sizes

Inverter type XTdor XTe-

Frame size

Maximum full load Amps

(continuous)

Fuse Amps (footnote) 90°C AWG

4004 1 4 5 (1) 14

4005 1 5.4 7 (1) 14

4009 1 9 12 (1) 12

4012 1 12 15 (1) 12

4016 2 16 20 (1) 12

4022 2 22 30 (1) 10

4031 3 31 40 (2) 10

4038 3 38 50 (2) 8

4045 3 45 60 (2) 8

4061 4 61 80 (2) 6

4072 4 72 90 (2) 6

4087 4 87 110 (2) 4

4105 5 105 125 (2) 2

4140 5 140 175 (2) 1/0

4168 5 168 200 (2) 1/0

4210 6 210 250 (2) 2/0

˜.(1) 600VAC time delay class CC fuses ˜.(2) 600VAC time delay class J fuses

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Owner's Manual


Frame sizes and installation of cables Note: In case you want to connect an external brake resistor, see separate Brake Resistor sizing chart located in this manual.

Drivecon XT, Frame size 1

Cable installation in Drivecon XT, Frame size 1 D-3

Owner's Manual


Drivecon XT, frame size 2. Protection class IP21

Cable installation in Drivecon XT, frame size 2

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Owner's Manual


Drivecon XT, Frame size 3. Protection class IP21

Cable installation in Drivecon XT, Frame size 3

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Owner's Manual


Drivecon XT, Frame size 4. Protection class IP21

Cable installation in Drivecon XT, Frame size 4

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Owner's Manual


Control unit

The control unit of the inverter consists roughly of the control board and additional boards (see Figure 4-7a and Figure 4-7b) connected to the five slot connectors (A to E) of the control board. The control board is connected to the power unit through a D-connector (1).

Figure D-7a Figure D-7b

Usually, when the inverter is delivered from the factory, the control unit includes at least the standard compilation of two basic boards (I/O board and relay board) which are normally installed in slots A, B, and D. On the next pages you will find the arrangement of the control I/ O and the relay terminals of the two basic boards, the general wiring diagram and the control signal descriptions. The I/O boards mounted at the factory are indicated in the type code.

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Owner's Manual


I/O and Relay Boards There are six cards available: NXOPTA6 this card plugs into slot A. Standard. No. Name Description, signal level No. Name Description, signal level

1 PUR Pull-up resistor for potentiometer 13 DIA3 Multi Function Input

2 +15V +15V 14 DIA4 Multi Function Input

3 AIN1+ Potentiometer speed reference, -10…+10V 15 DIA5 Multi Function Input

4 AIN2+ Analog reference, 0…+10V 10 +24V External supply for Control module

5 AIN- Analog reference, 0…+10V 11 S1 Forward Direction

6 AOUT1 Analog Output 1 12 S2 Reverse Direction

7 AOUT2 Analog Output 2, range 0…+10V 16 OK External control voltage, 48/115/230Vac

8 DOA1 DOA1 17 COM Neutral of external control voltage OK

9 0V Common for analog signals 18 COM Neutral of external control voltage OK

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Owner's Manual


NXOPTA3 this card plugs into slot B. Standard. No. Name Description, signal level No. Name Description, signal level

21 ROB1 NC contact of ROB1 25 ROB2 NO contact of ROB2 (brake relay)

22 ROB1 C contact of ROB1 26 ROB2 C contact of ROB2 (brake relay)

23 ROB1 NO contact of ROB1 28 T1 Thermistor input 1 29 T2 Thermistor input 2

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Owner's Manual


NXOPTB9 this card plugs into slot D. Standard.

No. Name Description, signal level No. Name Description, signal level

1 DID1 Multi Function Input 5 DID5 Multi Function Input

2 DID2 Multi Function Input 6 COM Neutral of external control voltage OK

3 DID3 Multi Function Input 7 ROD1 NO contact of ROD1

4 DID4 Multi Function Input 8 ROD1 C contact of ROD1

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Owner's Manual


Option Boards SSU this card plugs into slot C


1 EA+ Encoder channel A+ 5 +24V +24V output for encoder

2 EA- Encoder channel A 6 0V Common for encoder supply

3 EB+ Encoder channel B+ 28 ROC1 NO contact of SSU relay

4 EB- Encoder channel B 29 ROC1 C contact of SSU relay

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Owner's Manual


Option Boards Relay board this card plugs into slot E


22 ROE1 NO contact of ROE1 26 ROE2 C contact of ROE2

23 ROE1 C contact of ROE1 28 ROE3 NO contact of ROE3

25 ROE2 NO contact of ROE2 29 ROE3 C contact of ROE3

Profibus board this card plugs into slot E

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D-13

Owner's Manual


D14

Owner's Manual

Drivecon Toll Free Ph: 1-800-374-8266Drivecon, reserves the right to alter or amend the above information without notice

D15

Owner's Manual


D16

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D17

1 Owner's Manual


1 Description Functional description

See circuit diagrams for following descriptions of operation.

Operation when power is switched on

− Limit switches S11, S12, S21 and S22 are assumed to be closed, as well as the emergency stop button ES.

− The control voltage is supplied to A1 control inputs (external 42V…230V control voltage). The main voltage is connected to inverter power supply and inverter wakes up. If the control voltage is connected to RDY-signal and the fault circuit is OK, inverter is ready to operate in about 1-2 seconds.

− If either one of the direction signals S1 or S2 is on, the display shows F6 and running can begin only after the direction signals have been off for a while.

Normal operation – For the description of the speed reference setting see chapter 1.6

"Control methods". – Running starts when switch S1 (S2) closes. Closing the contact ROB2

on A1 energizes K7, which opens the brake (in models 055F-132F the brake can be controlled also by K71). XT Drive accelerate according to the acceleration ramp setting to the selected speed.

– When the switch S1 (S2) opens, XT Drive stop according to the deceleration ramp setting and the brake closes.

– R1 dissipate the regenerated energy during deceleration and lowering periods. The power supply to R1 is controlled by A1. If the braking resistor fan(s) are included in external resistor unit, they start to operate when power is supplied to the braking resistors. The cooling continues about 4-5 minutes after electrical braking to ensure that the temperature of the resistors drops below 150°C (302°F).

Other features – Slowdown limit switches S11 and S21 provide position dependent

frequency limiting. – Any reason, which opens the contact RDY, stops the operation of

inverter A1. – In case of overload, motor overheating etc. the hoisting can be

disabled by cutting the direction signal in terminal X1:8. – Thermistor relay function, which can be used when needed. – When the stop limit switch S12 or S22 opens, K7 (K71 in models

055F-132F) de-energizes and the mechanical brake stops the motion. – Independent speed supervision unit, SSU. – The speed measurement and supervision can be done either with

encoder, bearing encoder or proximity switch. The measured signals are square wave pulses. The frequency of the pulses is proportional to the speed of the motor and if the frequency is too high, overspeed is detected. If there are no pulses a stall situation is detected. If the actual speed differs too much from the supply frequency of the motor, the speed difference supervision stops the motion.

– Proximity switch buffer amplifier amplifies the sensor pulses and filters out disturbances. The amplifier is located close to the sensor.

– The extended speed range ESR can be used, if the signal FWE (field weakening enabled) is on. Then it is possible to run up to twice the nominal speed depending on the application.

2 Owner's Manual


Control methods There are four different control methods (command modes) available. All of them are available without any changes in the hardware or software. Any single XT Drive can be controlled either by a pushbutton controller in EP-mode, by a joystick type controller with a potentiometer located in the cabin in PO-mode or by a process computer in AU-mode. The only external device needed is a switch to select the desired control method. EP Electronic motor potentiometer function.

− Stepless control using a 2-step pushbutton controller. − EP3 stepless control using a 3-step controller.

PO Potentiometer control using a joystick type controller. − Requires a single 15V power supply (included in XT Drive). − Any additional amplifier is not needed.

AU Automation control − For any control device with an output in the range of 0-10V. − E.g. radio-controls, process computers.

MS Multistep control (2-4 steps as standard). − Requires programmable digital inputs for speed reference steps

(included in XT Drive).

Command mode selection

The command mode (EP, PO or AU) is selected by the switches CMS and AP. Normally the selection can be done only when the motion is stopped (not when running), but in special applications changing the mode is allowed during run by changing parameter values.

PO- and AU-modes PO- and AU-modes select either of the analog inputs for speed reference. Both analog inputs can be adjusted similar from 0V to 10V (radio or PLC-reference) or from 10V to 6.7V (potentiometer). As default, Ain1 is used in PO-mode and Ain2 is used in AU-mode.

Ain1 / PO Ain1 / PO Ain2 / AU Ain2 / AU Ain1 / PO

DIA3 AP not used AP not used AP not used AP = 0 AP = 1 DIA4 CMS not used CMS = 0 CMS = 1 CMS = 1 CMS = 1

EP-mode EP-mode selects the AP-button for speed reference. EP step 1 is command for minimum speed or hold speed. EP step 2 is the acceleration command.

EP step 1 EP step 2 EP step 1 EP step 2

DIA3 AP = 0 AP = 1 AP = 0 AP = 1 DIA4 CMS not used CMS not used CMS = 0 CMS = 0

Synchronization If required, two or more XT Drives can be run in precise synchronization. A separate synchronization controller is needed for this. The same speed reference (in EP- or PO-mode) is connected to every XT Drive and the correction signal for synchronization is connected to all XT Drive to input AIN2+. The speed reference signal of each XT Drive can also be modified separately by a PLC. Synchronization is activated by parameter selection.

3 Owner's Manual


Description of the control methods EP-control requires two 2-step pushbuttons, one for each direction. The operation is as follows: − the rest position means standstill (0-position) − during run the rest position means deceleration − step one (switch S1 or S2) means hold speed − when starting, step one means acceleration up to

the minimum speed − step two (switch AP) means acceleration (up to

the maximum speed if desired) − at the maximum speed step two means hold

speed, because the maximum speed cannot be exceeded

Pushbutton positionrest = decelerationstep 1 = hold speedstep 2 = acceleration

speed

pushbuttonposition

up / fwd

down / rev

time

EP-mode

EP3-control requires a 3-step controller. The operation is as follows: − the rest position means standstill (0-position) − step one (switch S1 or S2) is the minimum speed

command − step two (EP hold command) means hold speed − step three (switch AP) means acceleration (up to

the maximum speed if desired) − when releasing the controller, step one means

deceleration down to the minimum speed

speed

Pushbutton positionrest = stopstep 1 = minimum speedstep 2 = hold speedstep 3 = acceleration

pushbuttonposition

up / fwd

down / rev

time

EP3-mode PO-control requires a controller with potentiometer. The operation is as follows: − when the controller is at the rest position the

potentiometer is at the middle position causing zero speed

− run commands are controlled separately by closing the direction switches (S1 and S2)

− when the operator turns the controller to any direction, the speed increases

− the same turning angle of the controller causes a smaller change in speed, the closer the speed is to the minimum speed

AU-control requires an analog reference from radio or PLC. The operation is as follows: − the speed linearly follows the input signal. 0V

means zero speed and the higher the voltage, the higher the speed

− run commands are controlled separately by closing the direction switches (S1 and S2)

up / fwd

down / rev

speedspeed

controllerposition

time

potentiometer reference (controller position)or auxiliary reference

PO- and AU-modes

MS-control requires a 2-4-step controller. The operation is as follows: − each step has its own frequency − the frequencies are freely selectable − when controller is set to a certain step, the speed

changes to equal value

speed

controllerposition

up / fwd

down / rev

time

speed

controller position

MS-mode

4 Owner's Manual


Mechanical brake control The brake is controlled so that during starting the motor first generates torque and after that the brake is opened. The same applies for stopping; while the brake is being closed, the motor still generates torque. During a direction change, the brake is kept open all the time. XT Drive decelerates the motor to a stop according to the set deceleration time when the run command is switched off, so the brake is used only as a holding brake. This way brake wear is minimized. Only if a failure occurs or the emergency stop button is pushed, the brake closes immediately stopping the motor and the load. The motors of CXT-hoists and SM-trolleys have an electromechanical disk brake. The disk brake is opened and kept open during run by DC-voltage. When there is no voltage present the brake is closed and also kept closed by spring force. 2-phase AC - 002-045F

XT Scalar models 002F-045F include an AC-supply from two phases for the disk brake control. XT Drive controls this line and it is protected by an adjustable circuit breaker (max.4.0A). A rectifier included in the motor rectifies the AC-voltage to DC-voltage brake coils.

REC12 - 002-011F

XT Vector models 002F-011F have a built-in REC12 brake control unit, which is a line voltage half-wave rectifier (max.1.25Adc). The half-wave type rectifier reduces losses and is enough to open the brake. There is a contactor to switch the line voltage on and off. An external control unit is needed to control other brake types.

ESD141 - 015-110F

XT Vector models 015F-132F have a built-in ESD141 brake control unit, which is a line voltage full/half-wave rectifier (max.1.25Adc). Full-wave rectification is used to open the brake quickly. Then, the rectifier changes to a half-wave type, which reduces losses, but is enough to keep the brake open. There is a contactor to switch the line voltage on and off. The same contactor also disconnects the DC-voltage directly from the brake coil, which guarantees that the brake closes fast. An external control unit is needed to control other brake types.

3-phase AC - 055-110F - 055-110F

XT Drive models 055F-132F include a 3-phase AC-supply for the brake control. XT Drive controls this line and it is protected by an adjustable circuit breaker (max.4.0A). When a shoe brake is used, brake closing is speeded up by capacitors. They are connected in parallel with the brake via the brake contactor NC-contacts. The connection is partially ready in XT Drive. Only the capacitors must be added outside XT Drive. This connection can also be used to control 2-phase disk brakes or a separate KA372B brake control unit.

5 Owner's Manual


Motor control modes Open loop XT Drives have a built-in motor model, which calculates - one thousand times in a second - the values of the real motor. The input data needed for the calculation is the instantaneous value of the motor voltage from the ASIC and the measured motor current. Motor magnetic flux and shaft torque are calculated in the motor model based on the nameplate data of the motor.

Open loop vector control

Speedref

InverterAsic

CurrentVectorcalculation

SpeedControl

Torque

Flux

ref

M3~

Frequency control Open loop (mode 0)

In frequency control mode of Open Loop, the motor frequency follows the frequency reference signal. The actual rotating speed depends on load and is equal to the slip below or above the output frequency. Even with frequency control, the vector calculation is used to keep the magnetization at a correct level.

Current control Open Loop (mode 1)

In current control mode of Open Loop, the motor follows the frequency reference signal. The motor is current controlled in small frequencies (typically

6 Owner's Manual


EMC The shortening "EMC" stands for the Electro Magnetic Compatibility. According to the EMC directive "the apparatus shall be so constructed that: a) The electromagnetic disturbance it generates does not exceed a level allowing other apparatus

to operate as intended b) The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to

enable it to operate as intended."

Technical construction file

The technical construction file describes how the frequency converters have been constructed to comply with the directive and standard requirements.

Declaration of conformity

With the declaration of conformity the manufacturer informs that device is manufactured to fulfill required EMC standards.

CE-mark The CE marking is a declaration by a manufacturer or importer located in the European Economic Area that a product complies with the safety and health requirements of the directive in question. The manufacturer demonstrates for the authorities that the product complies with the safety requirements within the EU.

Environments Immunity and emission requirements are divided in two levels in the product standard according to the environments.

PDS

PDS

First environment means environment that includes domestic premises and also establishments directly connected to a low-voltage power supply network. XT Drives are not intended to be used on a low-voltage public network, which supplies domestic premises. Radio frequency interference is expected if used on such a network. Second environment means environment that includes all establishments other than those directly connected a low-voltage power supply network. Power drive system (PDS) means a system consisting of power and control equipment, including XT Drive.

Fulfilled EMC-standards Immunity XT Drives fulfill the immunity requirements defined in the EN 61800-3

Amendment 11 (2000) for the second environment.

Emissions XT Drives fulfill the emission requirements of the EN 61800-3 A11 2000 for the second environment.

Immunity level of second environment

Emission limit of second environment

Emission limit of first environment

Typical emission of XT Drive

Safety margin

Interferencelevel

Frequency

7 Owner's Manual


2 START-UP PROCEDURE If any problems or malfunctions occur during the start-up, refer to Chapter “Troubleshooting”, to find out the reason. All problems must be solved before continuing.

− Do not connect any voltage to the output terminals (U, V, W). Otherwise, the inverter will be

damaged. − The overload protection protects both the supply and the motor cables. The fuses of the supply

provide short circuit protection.

Visual checks – Record all checks and results. – Check condition of the cubicles. – Check that XT Drive serial number is the same as in the delivery documents. − Check the switch settings on SSU.

− If necessary, open the control box cover and adjust the SSU settings. − Check the cabling to the motor, brake, thermistors and speed sensor. − Check the motor type. − Check the wire terminations in the motor connection box

− Check connections for motor, thermistors, heaters, brake wear and speed sensor circuits. − Disconnect motor (U, V, W) and brake cables to prevent damage of the inverter. Measure the

isolation resistance of the brake coil and the motor windings (each phase to ground). − Re-connect motor and brake cables. − Check braking resistor(s). − Terminals X1:21-27 and X1:51-57 are for electronics level signals.

− Normally only shielded wires are connected to these terminals. Check that no control or line voltage level wires are connected there.

Checks before the first test run

Warning! High voltages inside the device.

− Check the power supply voltage (nominal voltage +/- 10%). – Make sure that run commands are off (pushbuttons / controller (master switch) at zero position). − Turn on the power from the main switch and the control voltage switch. – Within about 1 second the keypad should display "AC on", and then in about 1 second the

display changes to the motor output frequency "0.00" and the green READY status indicator turns on. – In a fault situation, the red FAULT status indicator blinks and the display shows a fault code

instead of frequency. − Check that the green RUN status indicator is off. − Check that the external connections and programming of digital inputs are according to the

application. − The parameters are properly set after factory tests and no adjustments are needed except for

the parameters that depend on the application and the motor. Write down in the parameter list all the values that have been changed.

Warning! High voltages inside the device. Wait for at least five minutes after the supply voltage has been switched off before doing any service actions. The display in the operating condition (lights on) indicates a dangerous voltage on the DC-bus. When display turns off, the DC-bus voltage is approximately 100V. Note also that there is always a dangerous voltage in the braking resistor when the DC-bus is charged.

8 Owner's Manual


Test run without load − Make sure that movement will not cause any danger to the environment or to the crane itself.

Avoid running close to the limit areas. − Check the limit switches manually if possible. − Check the run commands on the keypad display and correct the motor rotating direction. The

arrow rotates clockwise if S1 (fwd/up) is applied, and counter-clockwise if S2 (rev/down) is applied.

− Check the function of the speed sensor. − Check the function of the speed supervision circuit. − Run forward (upwards) at minimum speed for 5 to 10 seconds. Accelerate to full speed. Run 5 to

10 seconds. Stop. Repeat the same in the reverse (down) direction. Check the frequency display to make sure that the frequency changes through the whole operational frequency range from the minimum to the nominal speed.

− Check the motor operation (acceleration, deceleration and braking): accelerate to full speed forward (up), change to full speed reverse (down) and full speed forward (up) again and stop.

− Check the limit switch functions: run forward (up) slowly and check the slowdown and the stop limit switch operations. Re-check using full speed. Repeat the same check for the reverse (down) direction.

− If the optional ESR is used, check the maximum frequency.

Test run with load − Note, three loads are required:

− Nominal load (100%) for normal operation. − Limited load for ESR (optional). − An adequate extra load for dynamic overload testing and to test the ESR load limit.

− See the maintenance instruction HU1.03.0004 “Erection, Installation and Testing of EOT cranes” for the details of the load tests.

– Make sure that movement will not cause any danger to the environment or to the crane itself. − If the optional extended speed range (ESR) is used, check that the load limit is correctly set and

hoisting with bigger loads is prevented. – Run in both directions at minimum and maximum speeds. − If the fan tube resistor unit is included, check that the fan(s) starts to blow when running down

with nominal load and continues to blow for about 4-5 minutes after stopping.

After the test run – Record all the parameter value changes in the parameter list. – Make sure all remarks and setting values are recorded.

9 Owner's Manual


3. PARAMETER ADJUSTMENTS

Control keypad operation

Drive status indications : RUN Motor is running

Motor rotation direction STOP Inverter is not running READY AC power is on ALARM Warning is on FAULT Fault is on

Control place indications :

I/O term Terminals are the selected control place Keypad Control keypad is the selected control place Bus/Comm Control through Profibus is selected Text lines : Line 1 Location indication (parameter number) Line 2 Description line (parameter name) Line 3 Value line (parameter value) Status LEDs : ready green Illuminates the AC-supply is on run green Illuminates during run

KeypadI/O term

READY FAULTSTOPRUN ALARMBus/CommP3.4.1.1.

Motor Nom Volt 400 V

START

STOP

enterselect

reset

ready run fault

fault red Illuminates due to fault trip Button descriptions :

reset

Reset active faults START Starts the motor if the keypad is the active control location

select

Switch between two latest displays STOP

Stops the motor if the keypad is the active control location

enter Confirmation of selections Fault history reset

Browse up the menus Increase values

Move to previous menu level Move cursor left Exit edit mode

Browse down the menus Decrease values

Move to next menu level Move cursor right Enter edit mode

Warning! Running via keypad can cause a hazardous situation. Keypad control must not be

used.

10 Owner's Manual


Navigation on the control keypad

Letter front of the code number describes variable type B = Button G = Group N = Multimonitor T = Trip Counter C = Counter H = Fault History P = Parameter V = Value D = Data I = Info R = Reference E = Expander M = Menu Group S = System

READYSTOP

G3.

Parameters G1 G8

READYSTOP

G4.

Monitoring G1 G23

READYSTOP

G5.

Panel Control B1 R2

READYSTOP

M6.

System Menu S1 S8

READYSTOP

M7.

Active Faults F0

READYSTOP

M8.

Fault History H1 Hxx

READYSTOP

G3.4.

Motor Parameters G1 G7

READYSTOP

G3.4.1.

Motor Set 1 P1 G23

READYSTOP

P3.4.1.1.


READYSTOP

V4.22.

Output Frequency 0.00 Hz

READYSTOP

B5.1.

Panel ControlOff

READYSTOP

S6.2.

ApplicationCrane

READYSTOP

H8.1.

57 ThermistorF T1 T13

READYSTOP

Operation days 0

I/O term I/O term I/O term

I/O term

I/O term I/O term

I/O term I/O term

I/O term I/O term

I/O term I/O term I/O term I/O term

T8.1.1.

Value line editing

enter

Modechange

Acceptvalue

Editvalue

READYSTOP

P3.4.1.1.


I/O term

Warning! Changing parameter settings during running may cause a hazardous situation.

Parameter settings must not be changed during running.

Passwords Parameter Name Description

Following passwords release the parameter locks. Level 1 Locked 0 Level 2 Start-up 26

P3.1.1 Password

Level 3 Engineering 768

11 Owner's Manual


Monitoring

Below are listed the parameters of Group G4 Monitoring. For example, operation of analog and digital inputs can be verified with monitoring parameters. After power off and on the display returns as default to V4.22 Output Frequency. G4.1 Parameter Backup G4.7 Digital Input

B4.1.1 Load Default Par G4.7.1 DI StatusB4.1.2 Save User Par V4.7.1.1 S1B4.1.3 Load User Par V4.7.1.2 S2G4.1.4 Factory default V4.7.1.3 DIA3

B4.1.4 Save Default Par V4.7.1.4 DIA4G4.2 Analog I/O V4.7.1.5 DIA5

V4.2.1 Ain1 Value V V4.7.1.6 OKV4.2.2 Ain2 Value V V4.7.1.7 DID1V4.2.3 Aout1 Value mA V4.7.1.8 DID2V4.2.4 Aout2 Value V V4.7.1.9 DID3

G4.3 Relay Output V4.7.1.10 DID4V4.3.1 ROB1 State V4.7.1.11 DID5V4.3.2 ROB2 State K7 G4.7.2 DI FunctionV4.3.3 ROC1 State V4.7.2.1 DIA3 FunctionV4.3.4 ROD1 State V4.7.2.2 DIA4 FunctionV4.3.5 ROE1 State V4.7.2.3 DIA5 FunctionV4.3.6 ROE2 State V4.7.2.4 DID1 FunctionV4.3.7 ROE3 State V4.7.2.5 DID2 Function

G4.4 Operate Counters V4.7.2.6 DID3 FunctionOperate counters are not used V4.7.2.7 DID4 Function

G4.5 Fault Counter V4.7.2.8 DID5 FunctionR4.5.1 Fault Counter V4.7.3 Basic Board V4.5.2 Total Faults V4.7.4 Extension BoardV4.5.3 Selected Faults G4.8 SSU

G4.6 Bus Control V4.8.1 Overspd Lim 1 %V4.6.1 S1 V4.8.2 Overspd Lim 2 %V4.6.2 S2 G4.9 ServiceV4.6.3 Motor Set 2 V4.9.1 Phase U Curr AV4.6.4 Second Speed Lim V4.9.2 Phase V Curr AV4.6.5 Field Weakening V4.9.3 Phase W Curr AV4.6.6 Alt Control Mode V4.9.4 Encoder Speed HzV4.6.7 Brake Feedback G4.10 Sway controlV4.6.8 Ramp 2 V4.10.1 Swing Time sV4.6.9 Torque Limit V4.10.2 Pendulum Length mV4.6.10 AP V4.10.3 StoppingDistance mV4.6.11 Slow Limit S11 V4.11 Freq Ref HzV4.6.12 Slow Limit S21 V4.12 Speed Req HzV4.6.13 End Limit S12 V4.13 Distance Counter mV4.6.14 End Limit S22 V4.14 DC-link Voltage VV4.6.15 Brake Pedal V4.15 Heat Sink Temp °CV4.6.16 S-Curve Inhibit V4.16 MotorTemperature %V4.6.17 Tare V4.17 Motor Power %V4.6.18 Inching V4.18 Motor Voltage VV4.6.19 SlackCableByPass V4.19 Motor Torque %V4.6.20 Brake Pedal 2 V4.20 Motor Current AV4.6.21 Synchronizing V4.21 Motor Speed rpmV4.6.22 Speed Reference V4.22 Output Frequency HzV4.6.23 Torque Reference G4.23 MultimonitorV4.6.24 Speed Correction N4.23.1 MultimonitorV4.6.25 Ramp ReferenceV4.6.26 Torque Limit RefV4.6.27 Speed Limit RefV4.6.28 Load FeedbackV4.6.29 Sway Ctrl HeightV4.6.30 Calibration PosV4.6.31 Profibus Status

12 Owner's Manual


Parameter groups The parameters are assorted to groups. Beside is the group map of the parameters based on the software version Pro1V050. The groups are shown in control keypad according to the password level and the selected functions. All Groups are not always listed in control keypad. A sign of + in the front of the group code means that the group is visible in keypad, if the group function is selected.

G3 ParametersG3.1 Basic ParametersG3.2 I/O Parameters

G3.2.1 Digital InputsG3.2.2 Analog Input 1G3.2.3 Analog Input 2

+ G3.2.3.7 AU-Speed Ref+ G3.2.3.8 Torque Reference+ G3.2.3.9 Speed Correction+ G3.2.3.10 Torque Limit+ G3.2.3.11 Load Feedback

G3.2.4 Analog OutputG3.2.4.1 Aout1 FunctionG3.2.4.2 Aout2 Function

G3.2.5 Relay OutputsG3.3 Drive Control

G3.3.6 Limit Functions+ G3.3.7 Ramp2

G3.3.8 Advanced Ramps+ G3.3.9 Multistep+ G3.3.10 SSU

G3.3.11 Prohib Freq+ G3.3.12 Multicare

G3.3.12.1 Multicare 1G3.3.12.2 Multicare 2

G3.3.13 Torque ControlG3.3.14 Load ControlG3.3.15 Sway ControlG3.3.16 Joystick Filter

G3.4 Motor ParametersG3.4.1 Motorset 1

G3.4.1.21 AdditionalG3.4.1.22 ESRG3.4.1.23 Current Control

+ G3.4.2 Open Loop 1G3.4.2.1 U/f CurveG3.4.2.2 Brake ControlP3.4.2.3 OL Autotuning 1

+ G3.4.3 Closed Loop 1G3.4.3.5 Brake Control

+ G3.4.4 Motorset 2G3.4.4.21 AdditionalG3.4.4.22 ESRG3.4.4.23 Current Control

+ G3.4.5 Open Loop 2G3.4.5.1 U/f CurveG3.4.5.2 Brake ControlP3.4.5.3 OL Autotuning 2

+ G3.4.6 Closed Loop 2G3.4.6.5 Brake Control

G3.4.7 ExpertG3.4.7.2 Current Ctrl OLG3.4.7.3 Speed Ctrl CL

+ G3.5 Bus ParametersG3.5.2 DiagnosticG3.5.3 Bus Control

G3.6 ProtectionG3.7 Laboratory

+ G3.8 System BusG3.8.3 SynchronizationG3.8.4 Tandem

G4 MonitoringV4.22 Output Frequency Note! Returns automatically here.G4.1 Parameter Backup

G4.1.4 Factory DefaultG4.2 Analog I/OG4.3 Relay OutputG4.4 Operate CountersG4.5 Fault Counter

+ G4.6 Bus ControlG4.7 Digital Input

G4.7.1 DI StatusG4.7.2 DI Functions

+ G4.8 SSUG4.9 Service

+ G4.10 Sway ControlG4.23 Multimonitor

G5 Panel Control

M6 System MenuS6.3 Copy ParametersS6.4 ParamComparisonS6.5 SecurityS6.6 Keypad SettingsS6.7 HW SettingsS6.8 System Info

M7 Active Faults

M8 Fault History

13 Owner's Manual


4. COMPONENTS XT Drive Hoisting spare parts list

POS DESCRIPTION NAME REMARKS 002

003

004

005

007

011

015

018

022

030

037

045

055

075

090

110

132

A1 Inverter D2VxxxNF1e0# 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1(includes PSU and CSU)

Power supply unit PSUxxxNF1e# 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Fan D2VSP-EPP01060 24VDC 1 1 1 Fan D2VSP-EPP01061 24VDC 1 1 1 Fan D2VSP-EPP01062 24VDC 1 1 1 Fan D2VSP-EPP01063 24VDC 1 1 1 Fan D2VSP-ECP01038 230VAC 1 1 1 Fan D2VSP-EPP01080 230VAC 1 1Control unit CSU0# 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(includes boards A, B, D1) Display keypad D2VSP-ENXPAN_A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Basic I/O-board D2V-I/O_BOARD Slot A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Relay / Thermistor Board D2V-NXOPTA3 Slot B 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SSU D2V-SSU Slot C1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I/O Extension board D2V-NXOPTB9 Slot D1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Profibus Board D2V-NXOPTC5 Slot E1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Relay Extension Board D2V-NXOPTB5 Slot E2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

F7 Protective switch D2PS-GV2ME08 1 1 1 1 1 1 1 1 1 1 1 1 1at F7 Auxiliary contact D2PS-GV2AN20 1 1 1 1 1 1 1 1 1 1 1 1 1F71 Protective switch D2PS-GV2ME08 1 1 1 1 1

at F71 Auxiliary contact D2PS-GV2AN20 1 1 1 1 1

K7 Contactor D2K-LC1DT40D7 42VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1K7 Contactor D2K-LC1DT40E7 48VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1K7 Contactor D2K-LC1DT40F7 115VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1K7 Contactor D2K-LC1DT40P7 230VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

at K7 RC-filter D2K-LAD4RCE 42/48VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1at K7 RC-filter D2K-LAD4RCU 115/230VAC 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1at K7 Auxiliary contact D2K-LADT0 1 1 1 1 1 1 1 1 1 1 1at K7 Auxiliary contact D2K-LAD8N20 1 1 1 1 1 1 1 1 1 1 1 1

G1 Brake control unit D2BCU-REC12 1 1 1 1 1 1G1 Brake control unit D2BCU-ESD141 1 1 1 1 1 1 1 1 1 1 1

K71 Contactor D2K-LC1D09D7 42VAC 1 1 1 1 1K71 Contactor D2K-LC1D09E7 48VAC 1 1 1 1 1K71 Contactor D2K-LC1D09F7 115VAC 1 1 1 1 1K71 Contactor D2K-LC1D09P7 230VAC 1 1 1 1 1

at K71 RC-filter D2K-LAD4RCE 42/48VAC 1 1 1 1 1at K71 RC-filter D2K-LAD4RCU 115/230VAC 1 1 1 1 1at K71 Auxiliary contact D2K-LAD8N20 1 1 1 1 1at K71 Auxiliary contact D2K-LADN04 1 1 1 1 1

CM1 Y-capacitor D2F-KC-307-00 Supply network N 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1Z1 Ferrite D2F-RU2100-30-7 Supply network N 1 1 1 1 1 1Z2 Ferrite D2F-RH175285107 Supply network N 1 1 1 1 1 1Z3 Ferrite D2F-RH175285107 Supply network N 1 1 1 1 1 1Z1 Ferrite D2F-RU2101 Supply network N 1 1 1Z2 Ferrite D2F-74270096 Supply network N 1 1 1Z3 Ferrite D2F-7427015-2 Supply network N 1 1 1Z1 Ferrite D2F-RU2102 Supply network N 1 1 1Z2 Ferrite D2F-7427015 Supply network N 1 1 1Z3 Ferrite D2F-742701111-7 Supply network N 1 1 1Z2 Ferrite D2F-7427015-3 Supply network N 1 1 1 1 1Z3 Ferrite D2F-7427015-4 Supply network N 1 1 1Z3 Ferrite D2F-74270097-3 Supply network N 1 1Z4 Ferrite D2F-7427015-4 Supply network N 1 1Z4 Ferrite D2F-74270097-3 Supply network N 1

# defines special options ( 0 = none, 1 = varnished boards )

INVERTER

xxx defines inverter power rating class ( from 002 to 132 )e defines supply network ( 0 = unlimited, N = limited )# defines special options ( 0 = none, 1 = varnished boards )

# defines special options ( 0 = none, 1 = varnished boards )e defines supply network ( 0 = unlimited, N = limited )xxx defines inverter power rating class ( from 002 to 132 )

BRAKE SUPPLY CIRCUIT BREAKER

COMPONENTS FOR LIMITED SUPPLY NETWORK (GROUNDED)

SECOND BRAKE CONTACTOR

BRAKE CONTROL UNIT (DC-BRAKE)

BRAKE CONTACTOR (DC-BRAKE)

14 Owner's Manual


XT Drive Traverse spare parts list POS DESCRIPTION NAME REMARKS 00

200

300

400

500

701

101

501

802

203

003

704

505

507

509

011

013

2

A1 Inverter D2VxxxNF1e0# 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1(includes PSU and CSU)

Power supply unit PSUxxxNF1e# 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Fan D2VSP-EPP01060 24VDC 1 1 1 Fan D2VSP-EPP01061 24VDC 1 1 1 Fan D2VSP-EPP01062 24VDC 1 1 1 Fan D2VSP-EPP01063 24VDC 1 1 1 Fan D2VSP-ECP01038 230VAC 1 1 1 Fan D2VSP-EPP01080 230VAC 1 1Control unit CSU0# 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

(includes boards A, B, D1) Display keypad D2VSP-ENXPAN_A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Basic I/O-board D2V-I/O_BOARD Slot A 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Relay / Thermistor Board D2V-NXOPTA3 Slot B 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 SSU D2V-SSU Slot C1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 I/O Extension board D2V-NXOPTB9 Slot D1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Profibus Board D2V-NXOPTC5 Slot E1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Relay Extension Board D2V-NXOPTB5 Slot E2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

F7 Protective switch D2PS-GV2ME08 1 1 1 1 1 1 1 1at F7 Auxiliary contact D2PS-GV2AN20 1 1 1 1 1 1 1 1F71 Protective switch D2PS-GV2ME08 1 1 1 1 1

at F71 Auxiliary contact D2PS-GV2AN20 1 1 1 1 1

K7 Contactor D2K-LC1D09D7 42VAC 1 1 1 1 1 1 1 1 1 1 1 1K7 Contactor D2K-LC1D09E7 48VAC 1 1 1 1 1 1 1 1 1 1 1 1K7 Contactor D2K-LC1D09F7 115VAC 1 1 1 1 1 1 1 1 1 1 1 1K7 Contactor D2K-LC1D09P7 230VAC 1 1 1 1 1 1 1 1 1 1 1 1

at K7 RC-filter D2K-LAD4RCE 42/48VAC 1 1 1 1 1 1 1 1 1 1 1 1at K7 RC-filter D2K-LAD4RCU 115/230VAC 1 1 1 1 1 1 1 1 1 1 1 1

K71 Contactor D2K-LC1D09D7 42VAC 1 1 1 1 1K71 Contactor D2K-LC1D09E7 48VAC 1 1 1 1 1K71 Contactor D2K-LC1D09F7 115VAC 1 1 1 1 1K71 Contactor D2K-LC1D09P7 230VAC 1 1 1 1 1

at K71 RC-filter D2K-LAD4RCE 42/48VAC 1 1 1 1 1at K71 RC-filter D2K-LAD4RCU 115/230VAC 1 1 1 1 1at K71 Auxiliary contact D2K-LAD8N20 1 1 1 1 1at K71 Auxiliary contact D2K-LADN04 1 1 1 1 1

CM1 Y-capacitor D2F-KC-307-00 Supply network N 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1Z1 Ferrite D2F-RU2100-30-7 Supply network N 1 1 1 1 1 1Z2 Ferrite D2F-RH175285107 Supply network N 1 1 1 1 1 1Z3 Ferrite D2F-RH175285107 Supply network N 1 1 1 1 1 1Z1 Ferrite D2F-RU2101 Supply network N 1 1 1Z2 Ferrite D2F-74270096 Supply network N 1 1 1Z3 Ferrite D2F-7427015-2 Supply network N 1 1 1Z1 Ferrite D2F-RU2102 Supply network N 1 1 1Z2 Ferrite D2F-7427015 Supply network N 1 1 1Z3 Ferrite D2F-742701111-7 Supply network N 1 1 1Z2 Ferrite D2F-7427015-3 Supply network N 1 1 1 1 1Z3 Ferrite D2F-7427015-4 Supply network N 1 1 1Z3 Ferrite D2F-74270097-3 Supply network N 1 1Z4 Ferrite D2F-7427015-4 Supply network N 1 1Z4 Ferrite D2F-74270097-3 Supply network N 1

R1 Resistor D2REP90 Braking type B 1 1 1 1 2 2R1 Resistor D2REL42 Braking type B 1


INTERNAL BRAKING RESISTOR

COMPONENTS FOR LIMITED SUPPLY NETWORK (GROUNDED)

# defines special options ( 0 = none, 1 = varnished boards )

SECOND BRAKE CONTACTOR

BRAKE CONTACTOR

BRAKE SUPPLY CIRCUIT BREAKER

INVERTER


15 Owner's Manual


FAULT CODES If any of the following failures are found, the inverter displays the fault code and closes the mechanical brake causing the movement to stop. If several faults occur one after another, the latest one is displayed, the others are stored to fault history page. When inverter fault supervision trips, the FAULT indicator turns on and the blinking fault code “F xx“ (xx = fault number) appears on the display. XT Drive includes an automatic fault reset operation; the fault code stays on the display until the fault is removed and the controller released back to 0-position. Some of the fault codes require to switch the power off before run is possible. The faults are stored to the fault history, from there they can be seen if necessary. The fault history can store last 30 fault codes. Following exceptions exist when storing faults to the fault history 1. not stored faults: F6, F70 2. repeated faults are stored only once: F50, F51, F55, F60, F66, F71, F72

Fault code Possible cause Checking F 1 Overcurrent

Inverter has measured too high current (over 4*In) in the motor output: − sudden heavy load increase − short circuit in the motor or cable − not suitable motor − wrong motor parameters

Reset: switch power off and restart after the lamps of keypad are off. Check: − motor cable connection − motor and motor cable insulation − brake operation − motor loading − motor type and power rating − parameters

F 2 Overvoltage

DC-bus voltage has exceeded 135% maximum level, 911Vdc − supply voltage raised >1.35 x Un

(high overvoltage spikes at mains or not sinusoidal voltage wave form)

− deceleration time is too short

Reset has an additional 5 s time delay. Check: − adjust the deceleration time longer − measure main supply voltage level and wave

form while not running − motor insulation − motor cable insulation (phase-ground,

phase-phase) − braking resistor cable − braking resistor type and resistance − braking chopper operation

F 3 Earth fault

Current measurement has sensed unbalance in motor phase currents. Supervision level is 5% of inverter nominal current − not symmetric load − insulation failure in the motor or the

cables

Reset has an additional 5 s time delay. Check: − motor insulation − motor cable insulation (phase-ground,

phase-phase)

F 5 Charging switch

Charging switch is open when START command becomes active − interference fault − component failure

Check: − control unit and power unit connections − charging resistors If the fault comes again, change the control unit.

F 6 External Stop

Either the ES or RDY-signal has been tripped during run or SSU speed supervision unit has detect − OS overspeed supervision − ZS stall supervision − SD speed difference supervision Fault is not stored into fault history.

Check: − ES and RDY external connections − brake operation − pulse sensor/encoder function and cabling − measure pulse sensor/encoder pulses with

graphical multimeter or scope − SSU settings and SSU relay operation

16 Owner's Manual


Fault code Possible cause Checking F 7 Saturation trip

Very high overload or defective component

Reset: switch power off and restart after the lamps of keypad are off. Check: − motor and motor cable insulation − measure main circuit diodes and IGBT transistors If the fault comes again, change the D2V.

F8 System fault

System fault due to component failure or faulty operation.

Reset: switch power off and restart after the lamps of keypad are off. Check: − read fault extension code and contact authorized

service If the fault comes again, change the D2V.

F 9 Undervoltage

DC-bus voltage has dropped below 333Vdc − mains supply voltage interrupted − inverter fault can also cause an

undervoltage trip − external fault during run may cause an

undervoltage trip

In case of temporary supply voltage break, reset the fault and start again. Check mains input. − if mains supply is correct, an internal failure has

occurred − contact authorized service

F 10 Input line supervision

One input line phase is missing or supply voltage parameter is wrong

Check: − supply voltage − mains connection

F 11 Output phase supervision

Current supervision has sensed that one of the motor phases has no current

Check: − motor cable connections − measure motor phase currents and compare to

display value F 12 Braking chopper supervision

Braking chopper or braking resistor circuit has failed. Fault appears if − braking resistor is broken − braking chopper is broken − braking resistor is not installed

Reset: switch power off and restart after the lamps of keypad are off. Check: − braking resistor and cable resistance and

insulation resistance − measure braking transistor IGBT and free

wheeling diodes − if resistor is OK, then the chopper is broken − contact authorized service

F 13 Inverter undertemperature

Temperature of heat sink is below acceptable operating level -10°C (14°F)

Check − ambient temperature − cubicle heating − inverter cooling fan activation (continuous /

temperature limit) F 14 Inverter overtemperature

Temperature of heat sink is over acceptable operating level +90°C (194°F). Overtemperature warning is issued when the heat sink temperature exceeds +85°C (185°F)

Check: − ambient temperature − inverter cooling fan operation − cooling air flow through heat sink − heat sink is not dusty

F16 Motor overtemperature

Mathematical motor temperature model has detected motor overheating. Motor is overloaded.

Check: − motor load − if no overload exists, then check motor

temperature model parameters F 22 F 23 EEPROM checksum fault

Parameter save error − interference fault − component failure (control unit)

After power off the inverter will automatically load factory default parameter settings. XT Drive does not work properly nor enable running after this fault. Check: − all parameter settings − +24V voltage output loading If the fault comes again, contact authorized service.

17 Owner's Manual


Fault code Possible cause Checking F 24 Counter fault

Changes may have occurred in the different counter data due to mains interruption

No special actions required. Take a critical attitude to the counter data.

F 25 Microprocessor watchdog-fault

− interference fault − component failure (control unit)

If the fault comes again, read fault extension code and contact authorized service.

F 26 Power Unit Fault

Faulty power unit Contact authorized service.

F 31 IGBT temperature

Too high temperature in IGBT transistors. A hardware temperature measurement has tripped.

Reset: switch power off and restart after the lamps of keypad are off. Check: − motor loading − brake operation − inverter heatsink − inverter cooling fan operation − environment temperature

F 32 Fan cooling fault

Cooling fan of the frequency converter do not work, when ON command has been given

If the fault comes again, contact authorized service.

F 34 CAN bus communication

Sent message not acknowledged

Ensure that there is another device on the bus with the same configuration Check: − system bus

F 35 Application fault

Run-time exception in the application program

Contact authorized service.

F 36 Control Unit

Faulty Control Unit Contact authorized service.

F 37 Device changed

Option board or power unit has been changed to same type

Reset the fault.

F 38 Device added

Option board of same type or drive of same power rating added

Reset the fault.

F 39 Device removed

Option board removed. Drive removed.

Reset the fault.

F 40 Device unknown

Unknown option board or power unit.

Check the type of option board or control unit and power unit.

F 41 IGBT temperature

Too high temperature in IGBT transistors. − long duration overload − lowered cooling − high environment temperature

Reset: switch power off and restart after the lamps of keypad are off. Check: − motor loading − brake operation − inverter heatsink − inverter cooling fan operation − environment temperature

F 43 Encoder failure

Encoder failure. − Code1 = EA+/- is missing − Code2 = EB+/- is missing − Code3 = Both EA+/- and EB+/-

are missing − Code4 = EA+ and EB+ are

crossconnected

Check: − encoder cabling − brake opening − encoder mechanical assembly − encoder type and pulse number

F 44 Device changed

Option board or control unit has been changed to different type or different power rating

Reset the fault. Option board parameters or all parameters are set up to default values.

F 45 Device added

Option board of different type or drive of different power rating added

Reset the fault. Option board parameters or all parameters are set up to default values.

18 Owner's Manual


Fault code Possible cause Checking F 50 Reference value fault

Analog input signal is out of selected range 1-9V or 2-10V − control cable is broken − signal source has failed

Check − reference cable − reference source

F 53 Profibus communication error

Watchdog time out in Profibus communication. Effective only if control through Profibus is selected. Poor Profibus cable connection or communication problems with Profibus master.

Reset: switch power off and restart after the lamps of keypad are off. Check: − Profibus slave address − Profibus cable connection − Profibus termination resistor settings

F 55 Board Fault

Some of following board is missing: − A = Basic I/O board − B = Thermistor board − C = SSU (in closed loop and

hoisting applications)

Reset: switch power off and restart after the lamps of keypad are off. Check − board slots A, B and C − drive selection − control mode

F 56 Generator side current limit

Open loop frequency control only. Too short deceleration time or open loop generator side current limit is too low.

Reset has an additional 5 s time delay. Check: − deceleration time − current limit setting

F 57 Thermistor fault

Thermistor input in relay / thermistor board has detected motor overtemperature. Fault appears when thermistor input has been open over 1s.

Check: − motor cooling and loading − thermistor connection. If expansion board

thermistor input is not used, it should be shorted

− motor parameters − the brake operation

F 60 Parameter fault

Inverter has lost parameters. Drive selection parameter has changed to 0 / none.

Download parameters from keypad

F 61 Overspeed Fault

SSU has tripped to Overspeed (hardware supervision). Motor speed has increased above overspeed detection level.

Resets when 1s without pulses from pulse sensor/encoder to SSU and controller is at zero position. Check: − function and cabling − maximum frequency setting parameters − SSU settings

F 62 Speed Difference Fault

SSU has tripped to Speed Difference

Resets when 1s without pulses from pulse sensor/encoder to SSU and controller is at zero position.

drivecon xt series owner’s manualservice 21 . owner's manual drivecon toll free ph: 1-800-374-8266...

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