Drivecon XT Series User manual

Service Manual
9505 72nd Ave. Suite 100
Phone: [phone]
Fax: [phone]
www.drivecon.com
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Service Manual
Rev 6.0 with software Ind2V101
    

Drivecon Inc. reserves the right to alter or amend the above information without notice
// 2/59
Service Manual
Rev 6.0 with software Ind2V101


 Read the Instructions supplied with the hoist before installation, commissioning and servicing
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 Keep the instructions in a safe place for future reference.
1GENERAL ............................................................................................................................................................................. 5
1.1Technical data................................................................................................................................................................ 5
1.2Type mark coding........................................................................................................................................................... 6
1.3Basic description............................................................................................................................................................ 6
1.4Functional description .................................................................................................................................................... 6
1.5Description of the control modes.................................................................................................................................... 7
1.5.1EP2-control............................................................................................................................................................. 8
1.5.2EP3-control............................................................................................................................................................. 8
1.5.3MS4-control ............................................................................................................................................................ 8
1.6Mechanical brake control ............................................................................................................................................... 9
1.7EMC ............................................................................................................................................................................... 9
2INSTALLATION .................................................................................................................................................................. 10
2.1Power cabling............................................................................................................................................................... 10
2.1.1Shielded motor cable............................................................................................................................................ 10
2.1.2Double collectors.................................................................................................................................................. 10
2.1.3 4
th
Ground Conductor ............................................................................................................................................... 10
2.1.4Cable selection..................................................................................................................................................... 10
2.1.5Cable protection ................................................................................................................................................... 10
2.1.6 Cable length............................................................................................................................................................... 11
2.1.7 Du/dt filters................................................................................................................................................................ 11
2.2Signal cabling............................................................................................................................................................... 11
2.2.1Shielded signal cable............................................................................................................................................ 11
2.2.2Reference signals................................................................................................................................................. 11
2.2.3Sensor bearing ..................................................................................................................................................... 11
2.2.4Encoder ................................................................................................................................................................ 11
2.3EMC compatible grounding.......................................................................................................................................... 12
2.3.1Construction connections ..................................................................................................................................... 12
2.3.2Cable connections................................................................................................................................................ 12
2.3.3Shielded control cables ........................................................................................................................................ 12
3COMPONENTS ................................................................................................................................................................... 13
3.1Inverter ......................................................................................................................................................................... 13
3.1.1Power supply unit (PSU) ...................................................................................................................................... 14
3.1.2Control unit (CSU) ................................................................................................................................................ 14
3.1.3Basic I/O board (Slot A)........................................................................................................................................ 15
3.1.4Relay / Thermistor board (Slot B)......................................................................................................................... 15
3.1.5SSU Speed Supervision board (Slot C)................................................................................................................ 16
3.1.6I/O Extension board (Slot D)................................................................................................................................. 16
3.1.7System bus board (Slot E, option)........................................................................................................................ 17
3.2Control voltage transformer.......................................................................................................................................... 17
3.3Speed sensors ............................................................................................................................................................. 17
3.3.1Sensor bearing ..................................................................................................................................................... 17
3.3.2Encoder ................................................................................................................................................................ 18
3.3.3Proximity switch.................................................................................................................................................... 20
3.3.4Buffer amplifier KAE248 ....................................................................................................................................... 21
3.4Brake controllers .......................................................................................................................................................... 21
3.4.1REC12 .................................................................................................................................................................. 21
3.4.2ESD141 ................................................................................................................................................................ 22
4PARAMETER ADJUSTMENTS .......................................................................................................................................... 23
4.1The display panel ......................................................................................................................................................... 23
4.1.1Navigation on the control keypad ......................................................................................................................... 24
4.1.2Value line editing .................................................................................................................................................. 24

Drivecon Inc. reserves the right to alter or amend the above information without notice
//
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Service Manual
Rev 6.0 with software Ind2V101
4.2Storing and restoring parameters................................................................................................................................. 24
4.2.1User parameters................................................................................................................................................... 24
4.2.2Default parameters ............................................................................................................................................... 25
4.2.3Keypad settings .................................................................................................................................................... 25
4.2.4Factory settings .................................................................................................................................................... 25
5PARAMETER DESCRIPTIONS .......................................................................................................................................... 26
6FACTORY DEFAULT PARAMETERS ............................................................................................................................... 34
6.1Factory default parameters for 100Hz motors.............................................................................................................. 34
6.2Factory default parameters for 120Hz motors.............................................................................................................. 38
7SPEED SUPERVISION SETTINGS .................................................................................................................................... 42
7.1Standard settings ......................................................................................................................................................... 43
7.1.1Settings for sensor bearing................................................................................................................................... 43
7.1.2Settings for pulse wheel speed sensor or encoder (24 ppr) ................................................................................. 43
7.2Functional test run for SSU.......................................................................................................................................... 43
7.3Settings for non-standard cases .................................................................................................................................. 44
8SYNCHRO FUNCTION ....................................................................................................................................................... 45
8.1Function ....................................................................................................................................................................... 45
8.2Start-up ........................................................................................................................................................................ 46
8.3Optic cable connections............................................................................................................................................... 47
8.4Troubleshooting ........................................................................................................................................................... 47
9MULTICARE FUNCTION .................................................................................................................................................... 48
9.1Connections ................................................................................................................................................................. 48
9.2Setup............................................................................................................................................................................ 48
9.3Test run without load.................................................................................................................................................... 49
10START-UP PROCEDURE ............................................................................................................................................... 50
10.1Visual checks ............................................................................................................................................................... 50
10.2Checks before the first test run .................................................................................................................................... 50
10.3Test run without load.................................................................................................................................................... 50
10.3.1Functional test run for SSU .................................................................................................................................. 51
10.4Test run with load......................................................................................................................................................... 51
10.5Test run with overload.................................................................................................................................................. 51
10.6After the test run........................................................................................................................................................... 51
11TROUBLESHOOTING .................................................................................................................................................... 52
11.1Field repair actions....................................................................................................................................................... 52
11.2Typical functional problems.......................................................................................................................................... 52
11.3Inverter fault codes....................................................................................................................................................... 52
11.3.1Fault time data record........................................................................................................................................... 56
11.3.2Fault Counter........................................................................................................................................................ 57
11.4Inverter Alarm codes .................................................................................................................................................... 57
12TROUBLESHOOTING TABLE ....................................................................................................................................... 58
13SERVICE ......................................................................................................................................................................... 59
13.1DC-bus electrolytic capacitors...................................................................................................................................... 59
13.1.1Re-forming after a long storage period................................................................................................................. 59
T

Drivecon Inc. reserves the right to alter or amend the above information without notice
//
4/59
Service Manual
Rev 6.0 with software Ind2V101
This manual rev 6.0 is for inverter rev 5.1 with software Ind2V101.


 Before starting, read the instructions carefully.

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 Verify all of the connections are in accordance to the drawings.


 Verify the motor supply is connected correctly, faulty connection will destroy the inverter.
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 Check the device cover is properly installed.
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 High voltages are present in this device. Switch the power off and after the display turns off, wait 5 minutes
before opening the cover.

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 Insulation resistance test with a megger multimeter requires special precautions.


 Do not make any measurements inside the device when it is connected to the main supply.


 Do not touch the components on the circuit boards. Electrostatic discharge may cause damage or destroy the
IC-circuits.


 Check all ventilation holes are clear and unobstructed.


 Check that hot air coming from the brake resistors does not cause any danger.


 Do not make any inspections unless the supply has been disconnected by the main switch.

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 It is forbidden to use radiophones or portable phones near this device with the doors open.

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 All the doors and covers must be closed during crane operation.


 Drive is not intended to be used in a low-voltage public network, which supplies domestic premises. Radio
frequency interference is expected if used in such a network.

Drivecon Inc. reserves the right to alter or amend the above information without notice
//
5/59
Service Manual
Rev 6.0 with software Ind2V101
1 GENERAL
1.1 Technical data
Power class 4004 4005 4009 4012 4016 4022 4031 4038 4045 4061 4072 4087 4105
Horsepower 2 2 5 7.5 10 15 20 25 30 40 50 60 75
Output current In (A) 4 5.4 9 12 16 22 31 38 45 61 72 87 105
Max. current 1min (A) 6.0 8.1 13.5 18 24 33 46 57 67 91 108 130 157
Overloadability 1.5 x In , 1min/10min
Max. output voltage Equal to supply voltage
Supply
Supply voltage 380-500VAC
Allowable voltage fluctuation +/- 10%
Nominal supply frequency 50/60Hz +/- 5%
Signal input levels
Digital controls S1, S2, DIA3, DIA4, DIA5, DID1, DID2, DID3, DID4, DID5: 42 … 240VAC; 15mA
Encoder feedback EA+/- and EB+/-; 0/24V; 3kΩ; floating differential inputs
Control features
Control method Open loop vector control
Frequency control range 0 ... 250Hz
Frequency command Motor potentiometer or 2-4-step controller
Limit switch functions Slowdown and stop limit inputs for both directions
Speed control range s
N
... 100% (s
N
= motor nominal slip)
Speed accuracy 1% of nominal speed at speed range 10 ... 100%
1/3 of motor nominal slip at speed below 10%
Extended speed range 100 ... 200%
Braking torque 150%
Protections
Stall prevention During acceleration and constant speed
Motor overload protection Thermistor based temperature measurement
Overload protection Fault is detected if the current momentarily exceeds 280% of rated current
Undervoltage / blown fuse Fault is detected if DC voltage drops below 333V
Overvoltage protection Fault is detected if DC voltage exceeds 911V
Momentary power loss Immediate fault stop
Inverter overtemperature Temperature sensor on the heat sink
Mechanical brake Circuit breaker
Braking transistor Electronic supervision for the braking chopper and for the braking resistor
Ground fault Provided by electronic circuitry
Overspeed / stall,
Speed difference supervision Independent measurement using sensor bearing, pulse wheel or encoder
Ambient conditions
Ambient temperature -10°C ... +55°C (14°F ... 131°F) for ED≤60%
Storage temperature -40°C ... +60°C (-31°F ... 140°F) dry
Humidity <95%RH (no condensation)
Altitude Maximum 1000m at In. Above 1000m: In reduces 1% per each 100m.
Above 3000m: consult factory.
Vibration Operation: maximum displacement amplitude 3mm at 2-9Hz.
Maximum acceleration amplitude 0.5g (5m/s²) at 9-200Hz
Conforms to LV and EMC directives.

Drivecon Inc. reserves the right to alter or amend the above information without notice
//
6/59
Service Manual
Rev 6.0 with software Ind2V101
1.2 Type mark coding
XT drives can be summarized as a "crane hoisting and traveling motor control system, which controls the speed by
changing the frequency of supply voltage of a squirrel cage motor". A stepless speed adjustment can be achieved
by this method.
Type marking is shown below.
XT d 4 009 0 xx v x
XT Family Type
d d=scalar drive, e=vector drive, s=scalar panel, v=vector panel
r=regen base drive, I=inverter base drive, w= water cooled
4 Supply voltage
4=380 - 500VAC, 50/60Hz
009 Power class current handling type code
See technical specifications
0 Option PCB’s
0,1,2,3,4,5,6,7,8,9
xx Software revision
V Special options
V= Varnished
x Not used
1.3 Basic description
Inverter has many advantages and offers many new features, when compared to other inverter based systems, which might be
used in crane applications.
Inverter The specific crane features for the inverter hardware and the special software are achieved by combining the experience and
know-how of crane applications with the latest technology.
Crane user interface Interface with pre-
designed locations for typical crane functions. The main part of this interface is carried out by a terminal strip,
which has separated sections for signals with main, control and electronics voltage levels.
Brake control Includes the brake contactor for disk brakes. Includes also DC-rectifier.
Electrical Braking Includes a braking transistor and a braking resistor.
Control methods Can be controlled by
the electronic potentiometer control with 2-step or 3-step pushbuttons,
the multistep control with 2-4-step controllers.
Limit switch functions Built-in slowdown (S11, S21) and stop limit switch (S12, S22) functions for both running directions.
Speed supervision Inverter includes a speed supervision unit SSU, which is separate from the inverter and not dependent on software. This safety
circuitry is used to monitor the speed of the motor. In case of speed difference, overspeed or stall the speed supervision unit
stops the motion immediately.
Protections Includes a motor thermal protection, which is based on motor temperature measurement by Klixon placed in motor windings. A
great number of other protections included are shown in the technical data.
Tested parameters Inverter includes tested parameters with different motors for all power ratings. This is a benefit, which makes every inverter
delivery a proven solution. The tested and pre-set motor parameters enable a quick start-up in crane commissioning.
1.4 Functional description
Operation when power is switched on
- Stop limit switches S12 & S22 and slow down limit switches S11 & S21 are assumed to be normally closed, as well as the
emergency stop button ES.
- The control voltage is supplied to terminal A16. 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 of the direction signals S1 or S2 is on, the display shows F6 and driving can begin only after the direction signals
have been off for a while.

Drivecon Inc. reserves the right to alter or amend the above information without notice
//
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Service Manual
Rev 6.0 with software Ind2V101
Normal operation
- For the description of the speed reference setting see chapter "Control methods".
- Hoisting (lowering) starts when switch S1 (S2) closes. Closing the contact ROB2 on A1 energizes K7, which opens the
brake. Motor accelerates according to the acceleration ramp setting to the selected speed.
- When the switch S1 (S2) opens motor stops according to the deceleration ramp setting and the brake closes.
- R1 dissipates the regenerated energy during 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 contact RDY, stops the operation of inverter.
- 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, 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 sensor 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.
1.5 Description of the control modes
There are three different control methods (command modes) available:
1 EP2 Electronic motor potentiometer function.
Stepless control using a 2-step controller.
2 EP3 Electronic motor potentiometer function.
Stepless control using a 3-step controller.
3 MS Multistep control (4 steps)
The control mode of inverter is selected by parameter P2.1.4. See chapter Control methods. The parameters assigns digital
inputs S1, S2, OK, DIA3-DIA5 and DID1-DID5. It is not possible to chance the functions of the inputs separately. The state of
inputs can be checked from parameters V4.7.12 and V4.7.13. The input assignment according to the selected mode is
explained in the following table:
Control mode EP EP3 MS
Parameter P2.1.4 1 2 3
Signal Terminal
S1 A11 S1 S1 S1
S2 A12 S2 S2 S2
OK A16 OK OK OK
DIA3 A13 AP AP MS2
DIA4 A14 Not used HOLD MS3
DIA5 A15 Not used not used MS4
DID1 D1 FWE FWE FWE
DID2 D2 S11 S11 S11
DID3 D3 S21 S21 S21
DID4 D4 S12 S12 S12
DID5 D5 S22 S22 S22
Desired speed levels for multi-step control mode are selected with following parameters:
Speed Parameter Input
Speed 1 P2.2.8. / P2.2.9. S1/ S2
Speed 2 P2.1.7. MS 2
Speed 3 P2.1.8. MS 3
Speed 4 P2.1.9. MS 4

Drivecon Inc. reserves the right to alter or amend the above information without notice
//
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Service Manual
Rev 6.0 with software Ind2V101
1.5.1 EP2-control
c_coep2a
A. Pushbutton / controller position
B. Speed
0) “decelerate to zero”
1) while starting “drive minimum speed”
while running “hold speed”
2) while running “accelerate”
while running at maximum speed “hold speed”
1.5.2 EP3-control
c_coep3a
A. Pushbutton / controller position
B. Speed
0) “decelerate to zero”
1) step 1 “drive minimum speed”
2) step 2 “hold speed”
3) step 3 while running “accelerate”
while running at maximum speed “hold speed”
1.5.3 MS4-control
c_coms4b
A. Controller position
B. Speed
0) “decelerate to zero”
1) step 1 “drive minimum speed”
2) step 2 “drive speed2”
3) step 3 “drive speed3”
4) step 4 “drive maximum speed”

Drivecon Inc. reserves the right to alter or amend the above information without notice
//
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Service Manual
Rev 6.0 with software Ind2V101
1.6 Mechanical brake control
Inverter has a brake contactor to control electromechanical disk brake of hoisting motor. 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.
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. Inverter 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.
1.7 EMC
The abbreviated "EMC" stands for the Electromagnetic Compatibility. According to the European EMC directive "the apparatus
shall be so constructed that:
The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to operate as intended
The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to enable it to operate as intended."
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.
First environment means environment that
includes domestic premises and also
establishments directly connected to a low-
voltage power supply network.
PDS
Second environment means environment that
includes all establishments other than those
directly connected a low-voltage power supply
network
PDS
Fulfilled EMC-standards All products fulfil the immunity requirements defined in the EN 61800-3
Amendment 11 (2000) for the second environment.
N level products fulfil the emission requirements of the EN 61800-3 A11 2000 for
the second environment.

Drivecon Inc. reserves the right to alter or amend the above information without notice
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Service Manual
Rev 6.0 with software Ind2V101
2 INSTALLATION
2.1 Power cabling
2.1.1 Shielded motor cable
In crane application inverter fulfils EN61800-3/A11 (IEC 1800-3) second environment radiated emission requirements without
shielded motor cable.
In the second environment, shielded motor cable is recommended to use in fixed installations, especially in buildings. However
motor cables in crane and festoon power supplies are normally not shielded due to the practical reasons.
2.1.2 Double collectors
If the power is supplied to the crane via conductor rails, double collectors are needed. This ensures a reliable contact with the
rail in all circumstances. Short interruptions and sparks between the conductor rail and the collector may cause nuisance
tripping, other undesired operations and in worst case even permanent damage to components.
2.1.3 4th Ground Conductor
According to NEC article 409, all new installations are required to include a dedicated 4
th
conductor for the purposes of making
a reliable ground connection for the crane. Without a reliable ground connection, the crane must rely on the wheels of the
crane to provide a connection to ground. In this method, the connection is unreliable and can cause premature aging of the
bridge wheels and in the worst case cause permanent damage to electronic components.
2.1.4 Cable selection
Cabling for inverter can be done using normal crane cables. All the cables must be dimensioned according to local regulations.
Ambient temperature, cabling method (size of bunches etc.) and allowable current for the cable in use must be taken into
consideration. If there are no other regulations, following values can be used (three phase 460V supply).
The table below is based on ED 60% and ambient temperature +40°C (104°F). A higher ambient temperature may require
increased cable sizes. The input current does not exceed the continuous current (Icont) of inverter, so it is selected to be the
dimensioning current. If the actual load current is below inverter continuous current, then the fuses and the supply cable may
be dimensioned according to the load current.
Power class 4004 4005 4009 4012 4016 4022 4031 4038 4045
Max. motor cable length Ft 160 160 160 160 160 160 160 160 160
Motor wire size CMAA Class D 104
o
F AWG 14 14 14 14 12 10 8 8 6
Hoisting braking resistor wire
size CMAA Class D
104
o
F AWG 14 14 14 14 14 14 14 12 8
Traverse braking resistor wire
size CMAA Class D
104
o
F AWG 14 14 14 14 14 14 14 14 10
Power class 4061 4072 4087 4105
Max motor cable length Ft 160 160 240 240
Motor wire size CMAA Class D 104
o
F AWG 4 3 2 1/0
Hoisting braking resistor wire
size CMAA Class D
104
o
F AWG 8 4 4 3
Traverse braking resistor wire
size CMAA Class D
104
o
F AWG 10 8 8 6
2.1.5 Cable protection
To protect the supply cables against short circuit there must be fuses or motor circuit breakers (MCCBs) installed at the mains
end of the supply cable. Dimensioning of the fuses or MCCBs depends on the cable used and on the type of primary fuses or
MCCBs. If there are no other regulations, the values given in this section can be used to dimension fuses (three phase 400V
supply).
The overload protection of inverter protects both the supply and the motor cables. The fuses of the supply provide the short
circuit protection.

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//
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Service Manual
Rev 6.0 with software Ind2V101
2.1.6 Cable length
The maximum motor cable lengths in the preceding table are based on 150% of inverter rated current (=current during
acceleration) and a 2.5 % voltage drop in the cable. For longer cables, the required conductor cross sectional area A (mm2) is
given by formula
Up
Il
AF
×
×
×
×= 5.1 43.2
where lis the cable length (m)
I
F
is the motor current (A) at shaft power P
F
p is the allowed voltage drop in %
U is the nominal motor voltage
2.1.7 Du/dt filters
If inverter is not mounted on the crane, there has to be du/dt filter at motor supply. Also if total motor cable length (sum of
motor cables ) is over 100m with XT4004 – XT4012 or over 200m with XT4016 – XT4105, there has to be du/dt filter at motor
supply.


 Du/dt filter should be as near inverter as possible


 Note! All control cables must be placed as far from the motor and braking resistor cables as possible.
2.2 Signal cabling
2.2.1 Shielded signal cable
It's recommended to use twisted pair and braided shielded signal cables. Foil type shield is not sufficient enough in crane
applications because of poor mechanical durability. Cable insulation material effects to cable capacitance. Recommended
cable capacitance between signal-signal and signal-ground is equal or less than 100pF/m (31pF/ft).
It is not recommended to use shielded flat cable, because its capacitance is extremely high and this may cause high frequency
interference.
2.2.2 Reference signals
Shielded round cables must be used for analog reference signals. The shield is to be grounded only at one end of the cable.
2.2.3 Sensor bearing
The cable for the sensor bearings must be shielded round cable and grounded 360°at both ends.
2.2.4 Encoder
The encoder connections may be split into two cables, then the signal conductors (4pcs) should go together in one cable and
the supply and common (+24V/0V) together in another cable. The encoder cable(s) must be shielded round cable(s) and
grounded 360°at both ends.


 Note! All shielded cables must be placed as far from the motor cables as possible (>20cm). Shielding must be
continuous. The "pigtail" (= the end to be connected) of the shield should not be used, instead 360° grounding
should be used to minimize disturbances.


 If control cable length is over 100m (from transformer to inverter) or inverter is not mounted on the crane, make
sure that Basic I/O board (Slot A) is at least revision 271G and I/O Extension board (Slot D) is at least revision
266H

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//
12/59
Service Manual
Rev 6.0 with software Ind2V101
2.3 EMC compatible grounding
2.3.1 Construction connections
All metal construction parts of the cubicle must be electrically connected to each other using largest possible surface area.
Paint to paint connection must not be used.
2.3.2 Cable connections
Control cables and power cables should be separated and routed separately for eliminating noise coupling. The distance
between braking resistor cables and the other cables should be kept as long as possible. The distance between the resistor
cables should be kept as low as possible to prevent the antenna behavior. Cable lengths should be kept as short as possible
to minimize coupling capacitances and inductances.
2.3.3 Shielded control cables
Shielded control cables should be grounded in both ends. The shield must be connected to the ground using the largest
possible surface area. Extra intermediary terminators cutting the shield are not allowed, the shield should be as integrity as
possible. Spare conductors should be grounded in the both ends. All shielded cable shields should be 360°grounded.

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//
13/59
Service Manual
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3 COMPONENTS
3.1 Inverter
Inverter (XT) includes Power supply unit (PSU) and Control unit (CSU), which are separate parts. PSU includes
supply, brake resistor and motor connections. IGBTs are placed to PSU. Microprocessors and ASIC are placed to
CSU. Same CSU can be used in every power class.
XT
In
1min
Imax
Weight
kg
Weight
lbs
XT4004 4.0 6.0 6 13
XT4005 5.0 7.7 6 13
XT4009 9.0 13.2 6 13
XT4012 12 18 6 13
XT4016 16 24 10 22
XT4022 22 35 10 22
XT4031 31 47 20 44
XT4038 38 54 20 44
XT4045 45 68 20 44
XT4061 61 92 37 82
XT4072 72 108 37 82
XT4087 87 131 37 82
XT4105 105 158 61 135
e defines emission level ( 0 = EMC level 0, N = EMC level N/S )
The main circuit diagram of XT4004 – XT4012
L1
L2
L3
DC-
DC+
BR B+ B-
U/T1
V/T2
W/T3
WH_G
WH_D
WL_G
WL_D
VH_G
VH_D
VL_D
UL_G
UL_D
BRK_G
BRK_D
UH_D
UH_G
VL_G
The main circuit diagram of XT4016 – XT4105
DC-
DC+
BR B+ B-
WH_G
WH_D
WL_D
VH_G
VH_D
VL_G
VL_D
BRK_G
BRK_D
U/T1
V/T2
W/T3
L1
L2
L3
UH_D
UH_G
UL_G
UL_D
WL_G

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//
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Service Manual
Rev 6.0 with software Ind2V101
3.1.1 Power supply unit (PSU)
Power supply unit (PSU) includes the main circuit components. PSU has connectors for supply cables, motor
cables and braking resistor cables. PSU also includes a D-connector for CSU-connection.
Main supply voltage terminals
L1 Mains L1
L2 Mains L2
L3 Mains L3
PE Protective earth
DC-bus terminals
B- DC-bus negative
B+ DC-bus positive / Brake resistor positive
R- Brake resistor negative
Motor output voltage terminals
U/T1 Motor U
V/T2 Motor V
W/T3 Motor W
3.1.2 Control unit (CSU)
Control unit (CSU) includes a control board with five board slots for option boards and a control keypad for
parameter adjustments. CSU is connected to PSU through a D-connector.
Yellow Red Status
blinking
0.5Hz blinking 0.5Hz Everything is OK.
IEC Application Scheduler is running
and Application is running
blinking
0.25Hz blinking 0.5Hz IEC Application Scheduler is running and Application is NOT running
OFF blinking
0.5Hz IEC Application Scheduler and Application are NOT running
Green Status
ON PSU ready
OFF PSU not ready
YELLOW RED
GREEN
KEYPAD
A
BCDE

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//
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Service Manual
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3.1.3 Basic I/O board (Slot A)
Basic I/O-Board is in CSU slot A. It has two board levels, one for electronics level signals (terminals 1-10) and one
for control voltage signals (42-240Vac).
NXOPTA6 / Basic I/O board ID: 52288046
Terminal Signal name Description
1 PUR Not used
2 +15 V Not used
3 AIN1+ Analog input 1 (0-10V)
4 AIN2+ Not used
5 AIN- Common for analog input and output signals
6 AOUT1 Not used
7 AOUT2 Analog output 2 (0-10V)
8 DOA1 Not used
9 0V I/O ground terminal
10 +24V Not used
11 S1 Digital input 42-240Vac 50/60Hz (Direction S1)
12 S2 Digital input 42-240Vac 50/60Hz (Direction S2)
13 DIA3 Digital input 42-240Vac 50/60Hz
14 DIA4 Digital input 42-240Vac 50/60Hz
15 DIA5 Digital input 42-240Vac 50/60Hz
16 OK Digital input 42-240Vac 50/60Hz (OK-signal).
OK-input is connected straight to the ASIC.
Inverter is ready to operate when OK-signal is
active “1”.
17 COM Common for 42-240Vac 50/60Hz
18 COM Common for 42-240Vac 50/60Hz
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18
The threshold voltage for digital inputs S1, S2, DIA3, DIA4, DIA5 and OK is 35VAC.
3.1.4 Relay / Thermistor board (Slot B)
NXOPTA3 / Relay / Thermistor board ID: 52305690
Terminal Signal name Description
21 ROB1
22 ROB1
23 ROB1
Relay output, 250V 8A
25 ROB2
26 ROB2
Relay output, 250V 8A, normal open
28 T1
29 T2
Thermistor input, double isolated,
Rtrip=4.7kΩ
25 2621 22 23 28 29

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//
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Service Manual
Rev 6.0 with software Ind2V101
3.1.5 SSU Speed Supervision board (Slot C)
SSU is in CSU slot C, see chapter Speed supervision settings.
SSU / Speed supervision unit ID: 52288044
Terminal Signal name Description
1 EA+ Threshold voltage 10VDC
2 EA- Threshold voltage 10VDC
3 EB+ Threshold voltage 10VDC
4 EB- Threshold voltage 10VDC
5 +24V +24VDC short circuit protected
6 0V Common for encoder supply
28 ROC1
29 ROC1
Relay output, 250V 8A, normal open
Relay contact ROC1 closes when inverter is powered and no faults occurs
Relay contact ROC1 opens if the SSU has tripped in:
Overspeed
Speed difference
Zero speed
Relay test fault
Watch dog fault
LED Blinking Status
Red 1Hz OK
Yellow 0.25Hz OK
Yellow 4Hz Board internal fault or communication fault with control unit
1 2 3 4
ON OFF
S1
S2
S3
1 2 3 4 5 6
S1
S2
S3
RED
YELLOW
28 29
3.1.6 I/O Extension board (Slot D)
NXOPTB9 / I/O Extension board ID: 52305691
Terminal Signal name Description
1 DID1 Not used
2 DID2 42-240Vac 50/60Hz
3 DID3 42-240Vac 50/60Hz
4 DID4 42-240Vac 50/60Hz
5 DID5 42-240Vac 50/60Hz
6 COM Common for DID1-DID5
7 ROD1
8 ROD1
Relay output, 250V 8A, normal open
For fan of braking resistor unit
The threshold voltage for digital inputs DID1-DID5 is 35VAC.
LED Blinking Status
Yellow 0.25Hz OK
Yellow 4Hz Board internal fault or communication fault with control
unit
YELLOW
1 2 3 4 5 6 7 8

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Service Manual
Rev 6.0 with software Ind2V101
3.1.7 System bus board (Slot E, option)
NXOPTD1L System bus board ID: 52354858
Terminal Signal name Description
H1 RX1 SystemBus optical input 1.
H2 RX2 SystemBus optical input 2.
H3 RX3 SystemBus optical output 1.
H4 RX4 SystemBus optical output 2.
Optical cables
Specification ID: Length
[m] Bend radius
SYS-1M 52354911 1 > 35mm ( >1.3 inch)
SYS-2M 52354876 2 > 35mm ( >1.3 inch)
SYS-4M 52354912 4 > 35mm ( >1.3 inch)
H1 H2 H3 H4
3.2 Control voltage transformer
Power of control voltage transformer has to be n * 50VA + 50VA (min. 250VA), n = number of inverters. This power does not
have to be added to otherwise needed transformer power.
3.3 Speed sensors
3.3.1 Sensor bearing
Inverter needs information about the motor rotation speed for stall, speed difference and overspeed supervision. Order codes
of the bearing sensors are shown in the table below.
Sensor bearing requires KAE234 buffer amplifier. If channel A+ is damaged, channel B+ can be used instead in emergency
situations. With Synchro, both channels must be connected.
Signal name Sensor bearing
wire color
Wire color between KAE234 and
motor plug Terminal number
+24V Red Brown KAE234:6
0V Black Green KAE234:2
A+ White White KAE234:1
B+ Blue Not connected Not connected

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//
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Service Manual
Rev 6.0 with software Ind2V101
Standard connection with sensor bearing.
:55
+24V
:51
EA+
:54
EB-
INVERTER
black
+V
0V
red
:56
0V
:53
EB+
:52
EA-
G
white
A+
D2L X1
KAE 234
6
1
2
3
4
7
blue
B+
BROWN
GREEN
WHITE
Standard connection with sensor bearing. Two
channels connected for Synchro.
:55
+24V
:51
EA+
:54
EB-
INVERTER
:56
0V
:53
EB+
:52
EA-
D2L X1
black
+V
0V
red
G
white
A+
KAE 234
6
1
2
3
4
7
blue
B+
BROWN
GREEN
WHITE
KAE 234
6
1
2
3
4
7
YELLOW


 Critical damage if: The supply voltage is over 28V or a short circuit between the signal and the supply, or
induction heating or hammer mounting. In case of sensor damage, the whole motor has to be changed.
Buffer amplifier must be located as close to the sensor bearing as possible (maximum distance 2.5m)
The cable between the buffer amplifier and inverter must be
- as far as possible from the cables of motor and braking resistor (minimum distance >20cm)
- a shielded and twisted cable
- grounded (the shield) at both ends, 360 ° grounding on inverter terminal
- the shield should be grounded always when going through terminals
3.3.2 Encoder
Encoder connection examples are shown below. All signal wires shall be included inside a single shielded cable. Power supply
to the encoder may also be included in the same cable.

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//
19/59
Service Manual
Rev 6.0 with software Ind2V101
Standard connection
Encoder 24 ppr.
:55
+24V
:51
EA+
:54
EB-
INVERTER
blue
+V
0V
red
:56
0V
:53
EB+
:52
EA-
G
yellow
A+
terminal box D2L X1
Standard connection
Encoder 600 ppr. or more
:55
+24V
:51
EA+
:54
EB-
INVERTER
black
blue
+V
A-
0V
red
:56
0V
:53
EB+
:52
EA-
G
yellow
A+
green
B+
white
B-
terminal box D2L X1
In standard encoders, there are also "zero outputs (Z+, Z-)", which should be left disconnected. If the encoder does not have
negative channels (A- and B-), EA- and EB- must be connected to 0V at motor terminal box (alternative connection).
In order to avoid fault situations, the cable between the encoder and inverter must be
- as far as possible from the cables of motor and braking resistor (minimum distance >20cm)
- a shielded and twisted cable
- grounded (the shield) at both ends, 360 ° grounding on inverter terminal
- the shield should be grounded always when going through terminals
Some problems may occur when using shielded flat cable or in situations where the encoder cable has been placed too close
(< 5cm) to the motor cables and braking resistor cables.

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// 20/59
Service Manual
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3.3.3 Proximity switch
In modernisation cases there might be proximity switch as pulse sensor of motor.
Inverter needs information about the motor rotation speed for stall, speed difference and overspeed supervision. Type
markings of the speed supervision sensors (not needed in applications with bearing sensor or encoder) and fixing distance
from the pulse wheel (air gap) are shown in the table below.
Proximity switch air gap
Honeywell 3GT101DC 0.5 ... 1.0 mm
Schönbuch INSOR88 ICDM 8802 0.5 ± 0.1 mm
Baumer IFRM08N1501/L 0.5 ± 0.1 mm
Note that the Honeywell-sensor cable is lengthened and the wire colors are not equal to other
sensors. However, color markings corresponding to the other sensors have been added to
wire ends (not necessarily, if cable has been shortened afterwards). The connection of
Honeywell-sensor and the cable markings are shown in the table below.
Signal name Sensor Cable Color marking Terminal number
+24V Red Brown Brown KAE234:6
Honeywell 3GT101DC
5
12
35
29
PULSE Green Green Black KAE234:1
0V Black White Blue KAE234:2
Red
Green
Black
Brown
Green
White
6
1
2
3
4
7
+
0V
+15V
OUT
0V
Honeywell 3GT101DC
A5
INVERTER
+24V
EA+
OV
40
8
Schönbuch INSOR ICDM 8802
Brown
Black
Blue
6
1
2
3
4
7
+
0V
+15V
OUT
0V
A5
INVERTER
+24V
EA+
OV
M8x1
30
Baumer IFRM08N1501/L
Note the following details
- buffer amplifier must be located as close the proximity switch as possible (maximum distance 3m)
- sensor cable must be located as far from the motor cables and braking resistor cable as possible (minimum distance >
20cm)
In order to avoid fault situations, the cable between the encoder and inverter must be
- as far as possible from the cables of motor and braking resistor (minimum distance >20cm)
- a shielded and twisted cable
- grounded (the shield) at both ends, 360 ° grounding on inverter terminal
- the shield should be grounded always when going through terminals
Some problems may occur when using shielded flat cable or in situations where the encoder cable has been placed too close
(< 5cm) to the motor cables and braking resistor cables. Cabling methods and distances determine the best way to ground the
shielded cable; at both ends or only at one end.
Buffer amplifier pulse output can be measured during driving. If the pulse sequence is not uniform and for instance longer
pulses occur every now and then, the reason may be one of following:
- an incorrect air gap (proximity switch)
- the sensor is not properly on the top of the pulse wheel (proximity switch)
- disturbances are transferred to the sensor cable
- the pulse wheel is faulty
Honeywell 3GT101DC Hall-sensor requires tooth movement past the sensor. A motionless tooth can not gernerate a pulse.