Drivecon XT Series User manual

Service Manual
Rev 5.9A with software Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
XT SERIES
Service Manual
This document and the information contained herein,
is the exclusive property of Drivecon and represents
a non-public, confidential and proprietary trade secret
that may not be reproduced, disclosed to third parties,
altered, or otherwise employed in any manner whatsoever
without the express written consent of Drivecon.
Copyright © 2011 Drivecon. All rights reserved.
Quick Setup
Guides pg. 84

Page 1
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
This manual is valid for XT series drives revisions 5.9A. The parameter numbers
are based on the software version Pro3V120.
CAUTION
1. Before starting, read the instructions carefully.
2. Verify all of the connections are in done in accordance to the drawings.
3. Verify the motor supply is connected correctly; faulty connections will
damage the drive.
4. Check to make sure that the drive’s cover is properly installed.
5. High voltages are present in the drive. Switch the power off and 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
the 3-phase power supply.
8. Do not touch the components on the circuit boards. Static voltage discharge
may cause damage to the IC-circuits.
9. Check to make sure that all ventilation holes are clear and uncovered.
10. Check to make sure that hot air coming from the dynamic braking resistors
cannot cause any damage.
11. Do not make any inspections unless the supply has been disconnected at
the main disconnect switch.
12. It is forbidden to use radiophones or portable phones near this device with
the doors open.
13. All the doors and covers must be closed during crane operation.

Page 2
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
Table of contents
1 GENERAL ------------------------------------------------------------------------------------------------------- 4
1.1 Technical Data ------------------------------------------------------------------------------------------- 4
1.2 Type mark coding ---------------------------------------------------------------------------------------- 6
1.3 Basic description ----------------------------------------------------------------------------------------- 7
1.4 Functional description ----------------------------------------------------------------------------------- 8
1.5 Control Methods ------------------------------------------------------------------------------------------
9
1.6 Mechanical brake control ------------------------------------------------------------------------------- 11
1.7 Motor control modes ------------------------------------------------------------------------------------ 12
1.8 EMC -------------------------------------------------------------------------------------------------------- 13
1.8.1 Fulfilled EMC-standards ------------------------------------------------------------------------- 14
2 INSTALLATION ------------------------------------------------------------------------------------------------ 15
2.1 Cooling ----------------------------------------------------------------------------------------------------- 15
2.2 Power cabling --------------------------------------------------------------------------------------------- 16
2.3 Control wiring --------------------------------------------------------------------------------------------- 18
2.4 EMC compatible grounding ---------------------------------------------------------------------------- 18
2.5 SCCR rating ----------------------------------------------------------------------------------------------- 18
3 START-UP PROCECURE ----------------------------------------------------------------------------------- 19
3.1 Visual checks --------------------------------------------------------------------------------------------- 19
3.2 Check before the first run ------------------------------------------------------------------------------ 19
3.3 Test run without load ------------------------------------------------------------------------------------ 20
3.4 Test run with load ---------------------------------------------------------------------------------------- 20
3.5 After the test run and autotuning --------------------------------------------------------------------- 20
4 PARAMETER ADJUSTMENTS ----------------------------------------------------------------------------- 21
4.1 Control keypad operation ------------------------------------------------------------------------------- 21
4.1.1 Navigation on the control keypad -------------------------------------------------------------- 22
4.1.2 Value line editing ---------------------------------------------------------------------------------- 22
4.1.3 Passwords ------------------------------------------------------------------------------------------ 23
4.1.4 Special button functions and shortcuts ------------------------------------------------------- 23
4.1.5 Monitoring ------------------------------------------------------------------------------------------- 24
4.2 Input selections ------------------------------------------------------------------------------------------- 25
4.3 Speed supervision settings ---------------------------------------------------------------------------- 26
4.3.1 Functional test run for SSU --------------------------------------------------------------------- 28
4.4 Open Loop motor parameter adjustments ---------------------------------------------------------- 29
4.4.1 Open Loop speed control for hoisting -------------------------------------------------------- 29
4.4.2 Open Loop rated motor parameters for traveling ------------------------------------------- 29
4.4.3 Open Loop autotuning for traveling, frequency control ----------------------------------- 30
4.4.4 Open Loop manual tuning for traveling ------------------------------------------------------- 30
4.4.5 Open Loop manual tuning for traveling, frequency control ------------------------------ 31
4.4.6 Open Loop manual tuning for traveling, current control ---------------------------------- 31
4.5 Closed Loop motor parameter adjustments -------------------------------------------------------- 32
4.5.1 Closed Loop rated motor parameters --------------------------------------------------------- 32
4.5.2 Closed Loop autotuning, speed control ------------------------------------------------------- 34
4.5.3 Closed Loop manual tuning for hoisting, speed control ----------------------------------- 37
4.5.4 Brake Control -------------------------------------------------------------------------------------- 38
4.6 Brake Slip feature ---------------------------------------------------------------------------------------- 40
4.6.1 Description of brake slip feature --------------------------------------------------------------- 40

Page 3
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
4.6.2 Activation of brake slip feature ----------------------------------------------------------------- 41
4.6.3 Brake slip feature field testing procedure ---------------------------------------------------- 41
4.6.4 What to do in case of brake slip --------------------------------------------------------------- 43
4.6.5 Service on hoist motor/encoder/brake with Brake Slip feature active ------------------ 43
5 PARAMETER DESCRIPTIONS ----------------------------------------------------------------------------- 44
6 COMPONENTS ------------------------------------------------------------------------------------------------ 58
6.1 INVERTER ------------------------------------------------------------------------------------------------ 58
6.1.1 Power supply unit (PSU) ------------------------------------------------------------------------- 61
6.1.2 Control unit (CSU) -------------------------------------------------------------------------------- 61
6.1.3 Basic I/O board (Slot A) -------------------------------------------------------------------------- 62
6.1.4 Relay / Thermistor board (Slot B) -------------------------------------------------------------- 63
6.1.5 SSU Speed Supervision board (Slot C) ------------------------------------------------------- 63
6.1.6 I/O Extension board (Slot D) -------------------------------------------------------------------- 64
6.1.7 Relay Extension board (Slot E) ----------------------------------------------------------------- 64
6.1.8 Profibus board (Slot E) --------------------------------------------------------------------------- 65
6.1.9 System board (Slot D or Slot E) ---------------------------------------------------------------- 66
6.1.10 CANopen Board (Slot E) ------------------------------------------------------------------------- 67
6.2 Reference potentiometer ------------------------------------------------------------------------------- 68
6.3 Speed sensors -------------------------------------------------------------------------------------------- 69
6.3.1 Encoder --------------------------------------------------------------------------------------------- 69
6.3.2 Sensor bearing ------------------------------------------------------------------------------------- 70
6.3.3 Proximity switch ----------------------------------------------------------------------------------- 71
6.3.4 Buffer amplifier KAE248 ------------------------------------------------------------------------- 72
6.4 Brake controllers ----------------------------------------------------------------------------------------- 73
6.4.1 REC12-690+DC ----------------------------------------------------------------------------------- 73
6.4.2 ESD141 ---------------------------------------------------------------------------------------------- 73
7 TROUBLESHOOTING ---------------------------------------------------------------------------------------- 74
7.1 Field repair actions -------------------------------------------------------------------------------------- 74
7.2 Inverter fault codes -------------------------------------------------------------------------------------- 75
7.2.1 Fault time data record ---------------------------------------------------------------------------- 80
7.2.2 Fault Counter --------------------------------------------------------------------------------------- 81
7.3 Inverter alarm codes ------------------------------------------------------------------------------------ 82
8 SERVICE -------------------------------------------------------------------------------------------------------- 83
8.1 DC-bus electrolytic capacitors ------------------------------------------------------------------------ 83
8.1.1 Reforming after a long storage period -------------------------------------------------------- 83
9 QUICK SETUP GUIDES ------------------------------------------------------------------------------------ 84
XT Series Quick Setup Guide (Closed Loop) ----------------------------------------------------- 85
XT Series Quick Setup Guide (Traverse) ---------------------------------------------------------- 89
XT Series Quick Setup Guide (Loadbrake Hoist) ------------------------------------------------- 92
XT Series Quick Setup Guide (Open Loop Hoist) ------------------------------------------------ 95
10 WIRING DIAGRAMS ------------------------------------------------------------------------------------------ 98
•CONTROL UNIT CONNECTIONS ---------------------------------------------------- Inside Back Cover

Page 4
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
1
GENERAL
1.1 Technical data
Power Class (460-series)
4 0 0 4 4 0 0 5 4 0 0 9 4 0 1 2 4 0 1 6 4 0 2 2 4 0 3 1 4 0 3 8 4 0 4 5 4 0 6 1 4 0 7 2 4 0 8 7 4 1 0 5 4 1 4 0 4 1 6 8 4 2 1 0 4 2 4 5 4 3 0 0 4 3 8 5 4 4 6 0 4 5 9 0 4 6 5 0
Frame Size
F r4 F r4 F r4 F r4 F r5 F r5 F r6 F r6 F r6 F r7 F r7 F r7 F r8 F r8 F r8 F r9 F r9 F r10 F r10 F r10 F r11 F r11
Horsepower (Hp) at 460V
2 3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 200 250 300 350 500 550
Output Current In (A)
4.5 5.6 9 12 16 22 31 38 45 61 72 87 105 140 168 210 245 300 385 460 590 650
Max. Current 1min (A)
10 10 15 20 27 36 48 63 72 90 113 135 165 225 270 315 368 450 578 690 885 975
Max. Current 2s/20s (A)
11 11 18 24 32 46 62 76 92 122 144 174 210 280 336 349 444 545 697 832 1068 1177
Power Class (575-series)
5 0 0 5 5 0 0 7 5 0 1 0 5 0 1 3 5 0 1 8 5 0 2 2 5 0 2 7 5 0 3 4 5 0 4 1 5 0 5 2 5 0 6 2 5 0 8 0 5 1 0 0 5 1 2 5 5 1 4 4 5 1 7 0
Frame Size
F r6 F r6 F r6 F r6 F r6 F r6 F r6 F r7 F r7 F r8 F r8 F r8 F r9 F r9 F r9 F r9
Horsepower (Hp) at 575V
3 5 7.5 10 15 20 25 30 40 50 60 75 100 125 150 175
Output Current In (A)
5.5 7.5 10 13.5 18 22 27 34 41 52 62 80 100 125 144 170
Max Current 1min (A)
9 12 15 21 27 33 41 51 62 78 93 120 150 188 216 255
Max. Current 2s/20s (A)
11 15 20 27 36 44 54 68 82 104 124 160 200 213 245 289
Power Class (240-series)
2011 2012 2017 2025 2031 2048 2061 2075 2088 2105 2140 2170
Frame Size
Fr4 Fr5 Fr5 Fr5 Fr6 Fr6 Fr7 Fr7 Fr7 Fr8 Fr8 Fr8
Horsepower (Hp) at 230V
2.6 4 5.3 6.7 9.3 14.7 20.1 24.1 29.5 40.2 49.6 60.3
Output Current In (A)
11 12.5 17.5 25 31 48 61 75 88 105 140 170
Max Current 1min (A)
16.5 18.5 26 37 46 72 91 112 132 157 210 255
Overloadability 1.5 x In, 1min/10min; 2.0 x In, 2s/20s
Max. output voltage Equal to supply voltage
S
upp
l
y
Supply voltage 240-series 208-240VAC, 460-series 380-500VAC, 575-series 525-690VAC
Allowable voltage fluctuation +/- 10%
Nominal supply frequency 50/60Hz +/- 5%
S
i
gn
a
l
I
npu
t
L
e
v
el
s
Digital controls S1, S2, DIA3, DIA4, DIA5, DID1, DID2, DID3, DID4, DID5: 42 … 240VAC; 15mA
Analog references
AIN1: 0 … +10V and AIN2: -10 … +10V; 200k
Ω
load
;
accuracy 0.5%
Encoder feedback
EA+/- and EB+/-; 0/24V; 3k
Ω
load; floating differential inputs

Page 5
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
(Technical Data Continued)
C
on
t
r
o
l
feat
u
r
e
s
Control method Open loop or closed loop vector control
Frequency control range 0 ... 250Hz
Frequency command Potentiometer, motor potentiometer, 2-4-step controller or 0 ... 10V analog signal
Limit switch functions Slowdown and stop limit inputs for both directions
Speed control range Open loop vector control
s
N
... 100% (s
N
= motor nominal slip)
Closed loop vector control
0 ... 100%
Speed accuracy Open loop vector control
1% of nominal speed at speed range 10 ... 100%
1/3 of motor nominal slip at speed below 10%
Closed loop vector control
0.01% of nominal speed
Extended speed range 100 ... 200% programmable
Brak ing torque 150%
Pr
o
tecti
on
s
Stall prevention During acceleration and constant speed
Motor overload protection Thermistor/Klixon based temperature measurement
Overload protection Fault is detected if the current momentarily exceeds 280% of RMS rated current
Undervoltage / blown fuse Fault is detected if DC voltage drops below 183V (240-series), 333V (460-series), 460V (575-series)
Overvoltage protection Fault is detected if DC voltage exceeds 437V (240-series), 911V (460-series), 1200V (575-series)
Momentary power loss Immediate fault stop
Inverter overtemperature Temperature sensor on the heat sink
Mechanical brake Brak e contactor control relay
Brak ing transistor Electronic supervision for the brak ing chopper and for the brak ing resistor
Brak e slip protection Only in closed loop and if protection function enabled, also a programmable relay output
Ground fault Provided by electronic circuitry
Overspeed, stall, speed difference supervision
Independent measurement using SSU board and a pulse wheel or encoder
A
m
b
ie
n
t
c
ond
iti
on
s
Ambient temperature
-10
°
C ... +55
°
C (14
°
F ... 131
°
F) for ED
≤
60%
Storage temperature
-40
°
C ... +60
°
C (-31
°
F ... 140
°
F) dry. Power on >1h per year.
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 1mm at 3-15.8Hz.
Maximum acceleration amplitude 1G (9.81m/s²) at 15.8-150Hz

Page 6
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
1.2 Type mark coding
XT Series drives can be summarized as "crane motor control systems, which controls the speed by
changing the frequency of the supply voltage of a squirrel cage motor". A stepless speed adjustment can
be achieved by this method. Type marking is shown below.
000 XTx Device name
000 - Base Drive (430,440) or Pre-engineered Panel (488,489,etc…)
XT - Series name
x - d (Base drive vector), e (base drive vector with SSU board), s (open loop
vector panel), v (closed loop vector panel)
4Supply voltage
2 208 - 240VAC, 50/60Hz
4 380 - 500VAC, 50/60Hz
5
525
-
690VAC, 50/60Hz
009 Power class current handling type code
See technical specifications
TC
Panel Motion and Duty Class
XX=Base Drive only
TC=Traverse class C
TD=Traverse class D
HC=Hoist class C
HD=Hoist class D
58 Software Revision code
The latest revision may differ
000 XTx 4 009 TC 58 0 0 0 4
Construction
0 Basic wall mounted
1
Through panel
EMC-compatibility
0 IT Network (Americas)
N IEC 61800-3 Second Environment (Europe)
Option board configuration
0 Standard A, B, D
1 Standard with speed supervision A, B, C, D
2 Profibus A, B, D, E
3 Profibus with speed supervision A, B, C, D, E
6 Fiber Optics A, B, D, E
7 Fiber Optics with speed supervision A, B, C, D, E
8 Relay A, B, D, E
9
Relay with speed supervision
A, B, C, D, E
Special
1. NXP and normal boards
2. NXP and lacquered boards
3. NXP and fiber optic link and lacquered boards
4. NXP2 and normal boards
5. NXP2 and lacquered boards
6. NXP2 and fiber optic link and lacquered boards

Page 7
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
1.3 Basic description
XT Series drives have many advantages and offer many new features, when compared to other inverter
based systems, which might be used in crane applications.
Inverter The XT Series drive is a crane specific 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. The inverter uses vector calculations for several
different motor control modes in both open and closed loop.
Crane user interface All XT Series drives have exactly the same interface with pre-designed
locations for all 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 XT Series drive panels include a relay for brake contactor control. The
brake contactor then controls the “parking” brake on the motor whether it
is 3-phase AC, 1-phase AC, or a DC brake coil.
Electrical braking XT Series drives include an internal dynamic braking transistor, which is
dimensioned for all crane applications. The braking transistor will
dissipate regenerative energy through an external braking resistor. This
resistor is sized according to the drive voltage, power, and duty cycle.
Control methods XT Series drives can be controlled by the electronic potentiometer control
with 2-step pushbuttons (2 speed infinitely variable), the potentiometer
control with analog joystick-type control, the automation control with PLC
and radio controls, and by the multistep control with 2-5 step controllers.
Any two of these control methods is programmable and available with
every drive.
Limit switch functions XT Series drives will come preprogrammed for slowdown and stop limit
switch functions for both operating directions. If slowdown and/or stop
limit switches are not used, their inputs may be programmed to other
functions or to “not used”.
Speed supervision In a non-loadbrake hoisting application the drive must include an
overspeed detection device. In XT Series drives this is called a speed
supervision unit (SSU) and is separate from the drive and is 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. A SSU board is standard
with any non-load brake hoist however can also be supplied for this
application or any traveling application if requested.
Protections XT Series drives include motor thermal protection that is based on motor
temperature measurement by thermistors or klixons placed in the motor
windings. If this protection is not desired, it may be turned off in the
programming. All other protection functions are listed in the technical
data.

Page 8
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
1.4 Functional description
See circuit diagrams for following descriptions of operation.
Operation when power
is switched on
- Slow down limit switches S11 and S21, and stop limit switches S12 and
S22 are assumed to be normally closed, as well as the emergency
stop button ES.
- The control voltage is supplied to the drive’s control inputs (externally
supplied 42VAC…230VAC control voltage). When the supply voltage is
connected to the drive’s power supply, the inverter will power up. If the
control voltage ok and the ready circuit have all of their contacts
closed, drive will be ready to operate in about 1-2 seconds.
- If either one of the direction signals S1 or S2 is on during power up, the
display shows F6 and running can begin only after the direction signals
have been turned off for 300ms.
Normal operation –For the description of the speed reference setting options see chapter
1.5 "Control methods".
–Operation starts when one of the directional inputs is given to the drive.
The drive will then close the ROB2 relay and energize the K7 brake
contactor, which will cause the “parking” brake to open. The drive will
then accelerate according to the acceleration ramp settings to the
requested speed.
–When the directional input is removed from the drive, it will stop
according to the deceleration ramp settings and finish by controlling the
“parking” brake to set and hold the motor.
–The dynamic braking resistor will dissipate the regenerative energy
during deceleration and hoisting in the down direction. The power
supplied to the resistor is controlled by the drive. If the braking resistor
fan(s) are included in an external resistor unit, they will start to operate
when power is supplied to the braking resistors. The fan cooling will
continue for about 4-5 minutes after electrical regenerative braking to
ensure that the temperature of the dynamic braking resistors drops
below 150°C (302°F).
Other features –Slowdown limit switches S11 and S21 provide position dependent
frequency limiting.
–Any reason that causes the ready circuit to open will stop the operation
of drive and sets the mechanical “parking” brake.
–In case of an overload (motor overheating, etc.), the hoisting can be
disabled by removing the direction signal.
–Thermistor or Klixon interface function can be used when required.
–When the stop limit switch S12 or S22 opens, the brake contactor K7
de-energizes and the mechanical “parking” brake will stop the motion.
–Independent speed supervision unit (SSU) for applications with speed
feedback.
–The speed measurement and supervision can be done either using an
encoder, bearing encoder, or pulse sensor. 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 to the motor,
the speed difference supervision stops the motion.
–When using a proximity switch or bearing sensor, a buffer amplifier
should be used to amplify the sensor pulses and filter out disturbances.
This amplifier should be located as close to the motor as possible.

Page 9
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
1.5 Control methods
There are four different control methods (command modes) available. At any given time 2 different control
modes may be used. A selector switch and programming of the drive is required to select the desired
control method when using 2 different control modes. Instructions on how to program the drive for each
different type of control can be found below.
EP Electronic motor potentiometer function.
- Stepless control using a 2-step pushbutton controller (2 speed
infinitely variable).
- EP3 stepless control using a 3-step controller (3 speed infinitely
variable).
PO Potentiometer control using a joystick type controller.
- Requires a single 15V power supply (supplied by the drive).
- Additional amplifier is not required.
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 (2-5 steps as standard).
- Requires programmable digital inputs for each speed reference
step.
Command mode
selection
The command mode (EP, PO or AU) is selected by the CMS and AP
inputs to the drive. Normally the selection can be done only when the
motion is stopped (not when running), but in special applications it may be
possible.
PO- and AU-modes PO and AU modes select either of the analog inputs for speed reference.
Both analog inputs can be adjusted 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

Page 10
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
Synchronization If required, two or more XT Series drives can be run in precise digital
synchronization. A separate synchronization controller is needed for this.
The same speed reference (in EP- or PO-mode) and the correction signal
are connected to each drive. The speed reference signal of each drive
can also be modified separately by a PLC. Parameter selection and proper
tuning activate the synchronization functionality.
Description of the control methods
EP2-control requires two 2-step pushbuttons, one for
each direction. The operation is as follows:
- the rest position means standstill (0-position)
- while running the rest position means deceleration
- when starting, step one means acceleration up to
the minimum speed
- when running step one (switch S1 or S2) means
hold speed
- step two (switch AP) means acceleration (up to the
maximum speed if desired)
- at the maximum speed step two does nothing
because the maximum speed cannot be exceeded
Pushbutton position
rest = deceleration
step 1 = hold speed
step 2 = acceleration
speed
pushbutton
position
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 position
rest = stop
step 1 = minimum speed
step 2 = hold speed
step 3 = acceleration
pushbutton
position
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
speed
speed
controller
position
time
potentiometer reference (controller position)
or auxiliary reference
PO- and AU-modes

Page 11
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
MS-control requires a 2-5-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 drive
will either accelerate or decelerate to match the
requested speed
speed
controller
position
up / fwd
down / rev
time
speed
controller
position
MS-mode
1.6 Mechanical brake control
The brake is controlled so that, while starting, the motor generates torque first and then 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 held open. The drive will decelerate the motor to a stop according
to the set deceleration time when the run command is removed, so the brake is used only as a holding
brake. This way brake wear is minimized. Only if a fault occurs or the emergency stop button is pushed
will cause the brake to close immediately stopping the motor and the load.
All motors used on cranes should use some type of electromechanical brake. Different applications may
require a different type of brake. Also, different applications may require this brake to be used differently.
As a default, XT Series drive panels are wired to control a single-phase AC brake. If a 3-phase brake is
to be used, some wiring changes will be required. If a DC brake is being used, a brake rectifier will need
to be used. The type brake rectifier that is required will depend upon the size and voltage of the brake
coil.

Page 12
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
1.7 Motor control modes
Open loop
XT Series drives have a built-in motor model, which calculates - one thousand times per second - the
values of the 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 parameters taken from motor.
Open loop
vector control
Speed
ref
InverterAsic
Current
Vector
calculation
Speed
Control
Torque
Flux
ref
M
3~
Frequency control
Open loop (mode 0)
In Open Loop Frequency Control, the frequency supplied to the motor follows the
frequency reference signal given to the drive. 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 for optimized torque.
Current control
Open Loop (mode 1)
In Open Loop Current Control, the frequency supplied to the motor follows the
frequency reference signal given to the drive. The motor is current controlled in
smaller frequencies (typically <10Hz) and in higher frequencies the motor is
voltage controlled. The current control ensures that in small frequencies the
speed of the motor is almost independent of the load.
Closed loop
The closed loop vector control also includes a motor model, which has simpler configuration than the
open loop vector control. This is because an additional input data from the incremental encoder is
available, thus eliminating additional calculations inside the drive. This measurement of the rotation of the
motor is used as feedback to the motor model calculation and allows possibilities for additional checking
and fine adjustments of the motor control. This is how 1000:1 speed control is achieved.
Closed loop vector
control
Speed
ref InverterAsic
Current
Vector
calculation
Speed
Control
Torque
Flux
ref
Speed
G
M
3~
Speed control
Closed loop (mode 3)
In Closed Loop Speed Control, the frequency supplied to the motor follows the
frequency reference signal given to the drive. The drive adjusts the motor
frequency and with this function compensates the load-dependent slip. The slip
compensation keeps the actual shaft speed constant and independent of loading

Page 13
Service Manual
Pro3V120
Drivecon reserves the right to alter or amend the above information without notice. 11/22/11 • rev 5.9A for Pro3V120
conditions. With closed loop speed control it is even possible to reach zero
speed with full torque.
Torque control
Closed loop (mode 4)
In Torque Control, the shaft torque is kept equal to the reference signal provided
to the drive. The motor speed depends very much on loading conditions - for
example, an unloaded motor would run at full speed all the time. For safety
reasons, the speed is limited between adjustable minimum and maximum
speeds.
1.8 EMC
The abbreviation "EMC" stands for the Electro Magnetic Compatibility. The XT Series drives contain EMC
input filtering that reduces the voltage and current harmonics that are produced by the drive and
generated back into the power supply. The XT Series drives used in North America have this filtering
capacity modified to allow for the varying types and fluctuations in the power network. If the European
Union EMC standards are necessary, the power supply must meet minimum requirements and the drive
configuration for this must be specified when ordering.
According to the European Union 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.
EMC Plan EMC Plan for inverters is intend to use as a guide in cases when
disturbance problems appear in crane installations, in the crane itself or in
other devices in the installation environment.
Environments Immunity and emission requirements are divided in two levels in the
product standard according to the environments.

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PDS
PDS
First environment means an environment that includes domestic premises
and also establishments directly connected to a low-voltage power supply
network. The first environment is divided in to categories C1 and C2.
XT Series drives are not intended to be used on a low-voltage public
network, which supplies domestic premises. The drive may cause radio
frequency interference to other devices 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.
The second environment is divided in to categories C3 and C4.
If rated current of the crane supply is less than 400 A, the inverters belong
to the category C3; otherwise they belong to the category C4.
Power drive system (PDS) means a system consisting of power and
control equipment, including the XT Series drive.
1.8.1 Fulfilled EMC-standards
Immunity The XT Series drive fulfills the immunity requirements defined in the
EN/IEC 61800-3: 2004 for the second environment, EN 61000-6-1
(residential, commercial and light industry) and EN 61000-6-2 (industrial
environment).
Emissions The XT Series drive fulfills the emission requirements of the EN/IEC
61800-3: 2004 for the second environment. If a disturbance causes
problems the EMC Plan can be used as the guide to solve those.

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2 INSTALLATION
2.1 Cooling
The cooling requirements for XT Series drives vary by application. The actual thermal loading of the enclosure has to be
estimated based on the environmental conditions and duty cycles. The power losses of the drive are listed in the below
table for each power rating in units of Watts [W]. Cooling for models, which are installed in totally closed cubicles, should
be checked case by case with ambient temperatures above 110 degrees Fahrenheit.
Through panel mounted
Totally enclosed cubicle Through panel mounted Totally enclosed cubicle
Model ED40 ED60 ED100 ED40 ED60 ED100 Model ED40 ED60 ED100 ED40 ED60 ED100
4004 21 24 29 67 92 141 5003 18 19 21 56 64 80
4005 21 24 29 67 92 141 5004 19 21 23 67 81 108
4009 21 23 28 64 87 132 5005 20 22 26 76 94 130
4012 24 28 36 96 134 211 5007 22 25 30 93 120 174
4016 25 30 39 116 160 248 5010 24 28 35 115 153 229
4022 31 39 54 176 250 398 5013 27 32 43 146 199 305
4031 30 37 51 177 246 383 5018 31 38 53 185 258 403
4038 38 49 71 256 364 581 5022 35 44 62 220 310 491
4045 41 54 79 289 413 662 5027 39 50 73 264 376 600
4061 34 43 60 230 318 493 5034 44 58 86 332 471 748
4072 43 57 83 322 456 724 5041 50 67 101 392 561 899
4087 53 71 107 415 596 957 5052 57 76 114 598 791 1176
4105 54 72 108 570 749 1108 5062 65 89 136 684 920 1392
4140 73 101 156 763 1039 1591 5080 81 112 175 840 1153 1781
4168 89 125 197 927 1284 1999 5100 50 66 98 781 942 1264
4210 73 101 157 1013 1291 1845 5125 62 84 127 896 1114 1551
4245 89 125 196 1170 1526 2237 5144 70 97 149 983 1245 1769
5170 82 115 179 1103 1424 2068
Note! The power losses given above do not include the power fed to the dynamic braking resistors. Check
each application that requires the dynamic braking resistor to be installed in the same enclosure as
the drive.

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2.2 Power cabling
Shielded
motor cable
In crane applications the drive fulfills EN/IEC 61800-3: 2004 second environment radiated
emission requirements without a shielded motor cable. However, shielded motor cable is
recommended to be used in fixed installations, especially in buildings.
In the second environment, shielded motor cable is recommended to be used in fixed installations,
especially in buildings. However motor cables in crane and festoon power supplies are normally
not shielded due to the practicality of it.
Shielded motor cable is essential to use if the installation is requested to fulfill the first
environment emission requirements.
Double
collectors
If the power is supplied to the crane via conductor rails, double collectors are required. 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
operation, and in some cases even cause permanent damage to the drive components.
Cable
selection
Cabling for the drive 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 480V/575V supply).
The table below is based on ED less than or equal to 60% and ambient temperature
+40C (104F). A higher ambient temperature may require increased cable sizes. The
input current does not exceed the continuous current (Icont) of the drive, so it can be
used as the dimensioning current. If the actual load current is below the drive’s rated
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
Continuous current I
CONT
A 4.5 5.5 9 12 16 22 31 38
Motor cable 104
o
F AWG 14 14 14 14 14 14 12 10
Braking resistor cable for hoist
CMAA Class D SRML Cable 104
o
F AWG 14 14 14 14 14 14 14 14
Braking resistor cable for travel
CMAA Class D SRML Cable 104
o
F AWG 14 14 14 14 14 14 14 14
Power class 4045 4061 4072 4087 4105 4140 4168 4210
Continuous current I
CONT
A 45 61 72 87 105 140 168 210
Motor cable 104
o
F AWG 8 6 6 4 2 1 1/0 2/0
Braking resistor cable for hoist
CMAA Class D SRML Cable 104
o
F AWG 10 8 6 6 4 1/0 1/0 1/0
Braking resistor cable for travel
CMAA Class D SRML Cable 104
o
F AWG 10 8 6 6 4 2 2 2
Power class 5005 5007 5010 5013 5018 5022 5027 5034
Continuous current I
CONT
A 5.5 7.5 10 13.5 18 22 27 34
Motor cable 104
o
F AWG 14 14 14 14 14 10 10 8
Braking resistor cable for hoist
CMAA Class D SRML Cable 104
o
F AWG 14 14 14 14 14 14 14 10
Braking resistor cable for travel
CMAA Class D SRML Cable 104
o
F AWG 14 14 14 14 14 14 14 12

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Power class 5041
5052 5062 5080 5100 5125 5144 5170
Continuous current I
CONT
A 41 52 62 80 100 125 144 170
Motor cable 104
o
F AWG 8 4 4 2 2 2/0 2/0 3/0
Braking resistor cable for hoist
CMAA Class D SRML Cable 104
o
F AWG 8 6 6 4 2 1 1/0 2/0
Braking resistor cable for travel
CMAA Class D SRML Cable 104
o
F AWG 10 10 8 6 4 4 1 1/0
**For wire sizing information for higher duty cycles and/or drives larger than listed
above, please contact Driecon.
Cable
protection
To protect the supply cables from a short circuit there must be fuses or motor circuit
breakers (MCCBs) installed at the supply end of the power cable. Sizing 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 size
the fuses (three phase 480V/575V supply).
The overload protection of the XT drive protects both the supply and the motor
cables. The fuses on the power supply provide short circuit protection.
Cable length The maximum motor cable length is 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 the following
formula:
A = 2.43*[( l * 1.5 * IF) / (p * U)]
where lis the cable length (m)
IFis the motor current (A) at shaft power PF
p is the allowed voltage drop in %
U is the nominal motor voltage
Note! All control wires must be placed as far away from the motor and braking resistor wires
as possible.
2.3 Control wiring
Shielded signal cable It's recommended to use twisted pair and braided shielded signal cables.
Foil shields are not sufficient enough in crane applications because of its
poor mechanical durability. The cable insulation material affects the cable
capacitance. The 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 thus may cause high frequency interference.
Reference signals Shielded round cables must be used for analog reference signals. The
shield is to be grounded only at the drive (not at the other end of the
cable).
Bearing sensor/Pulse
sensor
The cable for bearing sensors or pulse sensors must be shielded round
cable and should be 360°grounded at both ends.

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Encoder The encoder connections may be split into two cables. 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 should be 360 degree grounded 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 degree grounding should be used to minimize
disturbances to the low voltage signals.
2.4 EMC compatible grounding
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.
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 the noise effects that can come from
coupling capacitances and inductances between the wires.
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. Spare
conductors should be grounded in both ends to avoid antenna behavior.
All shielded cable shields should be 360°grounded.
2.5 SCCR Rating
D2V frequency converters have an integral solid state short circuit protection. According to our UL
certification, D2V can adopt high SCCR (Short Circuit Current Rating) ratings according to the branch
circuit protection device protecting the D2V. The D2V units are suitable for use on a circuit capable of
delivering not more than 100,000 rms symmetrical amperes, 600V maximum.

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3 START-UP PROCEDURE
If any problems or malfunctions occur during the start-up, refer to the “Troubleshooting” chapter to find
hints on correcting the problem. All problems must be solved before continuing.
- Do not connect any voltage to the output terminals (U, V, W). This will cause damage to the drive.
- The overload protection protects both the supply and the motor cables. The fuses in the power supply
provide short circuit protection.
3.1 Visual checks
- Record all checks and results.
- Check condition of the enclosures.
- Make sure that the drive serial number is the same as in the delivery documents.
- Check the rotary dial and dip switch settings on the SSU board (see chapter "SSU").
- If necessary, open the control box cover and adjust the SSU settings.
- Check the wiring to the motor, brake, thermistors and speed sensor.
- Check the motor type and motor parameters
- 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 (using a megger) of the brake coil and the motor windings (each phase to ground).
- Re-connect motor and brake cables.
- Check braking resistor(s) and resistor enclosure air ventilation.
- The temperature of hot air coming from braking resistors may rise over 200C (400F). Make sure
that hot air does not cause any danger.
- A board terminals A1-A10 and C board terminals C1-C6 are for electronics level signals.
- Normally only shielded wires are connected to these terminals. Make sure that no control or line
voltage level wires are connected there.
3.2 Checks before the first test run
Warning! High voltages inside the device.
- Make sure that the power supply voltage is sufficient (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
should change to the multimonitor parameter 4.23.1 and the green READY status indicator should also
turn on.
- In a fault situation, the red FAULT status indicator blinks and the display shows a fault code instead
of the multimonitor.
- Make sure that the green RUN status indicator is off.
- Make sure that the external connections and programming of the digital and analog inputs are done
according to the application requirements.
Warning! High voltages inside the device. Wait for at least five minutes after the supply voltage
has been switched off before performing 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.