Drivecon XT Series User manual

Service Manual
Pro2V070
XT Series rev 5.5B Pro2V070
XT SERIES
Service Manual
820 Lakeside Drive –Gurnee, IL 60031
Phone: [phone]
Fax: [phone]
www.drivecon.com

Page 1Service Manual Pro2V070
Drivecon Inc. reserves the right to alter or amend the above information without notice 21.12.2004 • XT SERIESCSM55BEN
?CAUTION
1. Before starting, read the instructions carefully.
2. Verify all of the connections are in accordance to the drawings.
3. Verify the motor supply is connected correctly; faulty connection will
destroy the inverter.
4. Check the device cover is properly installed.
5. High voltages are present in this device. Switch the power off and after
the display turns off, wait 5 minutes before opening the cover.
6. Insulation resistance test with a megger requires special precautions.
7. Do not make any measurements inside the device when it is connected
to the main supply.
8. Do not touch the components on the circuit boards. Static voltage
discharge may cause damage or destroy the IC-circuits.
9. Check all ventilation holes are clear and uncovered.
10. Check that hot air coming from the brake resistors does not cause any
danger.
11. Do not make any inspections unless the supply has been disconnected
by the main 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.
?
This manual is valid for XT Series revisions 5.5. The release number of this document is XT
SERIESCSM55BEN. The parameter numbers are based on the software version Pro2V070.
?

Page 2Service Manual Pro2V070
Drivecon Inc. reserves the right to alter or amend the above information without notice 21.12.2004 • XT SERIESCSM55BEN
CONTENTS
1GENERAL.......................................................................................................................4
1.1 Technical data.......................................................................................................4
1.2 Type mark coding..................................................................................................5
1.3 Basic description ...................................................................................................6
1.4 Main components ..................................................................................................7
1.5 Functional description............................................................................................8
1.6 Control methods ....................................................................................................9
1.7 Mechanical brake control .....................................................................................12
1.8 Motor control modes ............................................................................................13
1.9 EMC ...................................................................................................................14
1.9.1 Fulfilled EMC-standards ............................................................................14
2INSTALLATION .............................................................................................................16
2.1 Cooling...............................................................................................................16
2.2 Power cabling......................................................................................................16
2.3 Control wiring......................................................................................................19
2.4 EMC compatible grounding...................................................................................19
3START-UP PROCEDURE...............................................................................................20
3.1 Visual checks ......................................................................................................20
3.2 Checks before the first test run.............................................................................20
3.3 Test run without load ...........................................................................................21
3.4 Test run with load................................................................................................21
3.5 After the test run .................................................................................................21
4PARAMETER ADJUSTMENTS........................................................................................22
4.1 Control keypad operation .....................................................................................22
4.1.1 Navigation on the control keypad ...............................................................23
4.1.2 Value line editing......................................................................................23
4.1.3 Passwords................................................................................................24
4.1.4 Special button functions ............................................................................24
4.1.5 Monitoring................................................................................................25
4.2 Input selections ...................................................................................................26
4.3 Speed supervision settings...................................................................................27
4.3.1 Functional test run for SSU........................................................................29
4.4 Open Loop motor parameter adjustments ..............................................................30
4.4.1 Open Loop speed control for hoisting .........................................................30
4.4.2 Open Loop rated motor parameters for traveling .........................................30
4.4.3 Open Loop autotuning for traveling, frequency control.................................32
4.4.4 Open Loop manual tuning for travelling ......................................................32
4.4.5 Open Loop manual tuning for traveling, frequency control............................34
4.4.6 Open Loop manual tuning for traveling, current control................................34
4.5 Closed Loop motor parameter adjustments............................................................36
4.5.1 Closed Loop rated motor parameters..........................................................36
4.5.2 Closed Loop autotuning, speed control .......................................................37
4.5.3 Closed Loop manual tuning for hoisting, speed control ................................41
5PARAMETER DESCRIPTIONS .......................................................................................44
6COMPONENTS .............................................................................................................58
6.1 Inverter...............................................................................................................58
6.1.1 Power supply unit (PSU)............................................................................60
6.1.2 Control unit (CSU) ....................................................................................60

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6.1.3 Basic I/O board (Slot A) ............................................................................61
6.1.4 Relay / Thermistor board (Slot B)...............................................................62
6.1.5 SSU Speed Supervision board (Slot C).......................................................62
6.1.6 I/O Extension board (Slot D)......................................................................63
6.1.7 Relay Extension board (Slot E) ..................................................................63
6.1.8 Profibus board (Slot E)..............................................................................65
6.2 Reference potentiometer......................................................................................67
6.3 Speed sensors.....................................................................................................69
6.3.1 Encoder (if applicable) ..............................................................................69
6.3.2 Sensor bearing (if applicable) ....................................................................71
6.3.3 Proximity switch (if applicable) ..................................................................72
6.3.4 Buffer amplifier KAE234 (if applicable).......................................................73
6.4 Brake controllers .................................................................................................75
6.4.1 REC12-690+DC ........................................................................................75
6.4.2 ESD141....................................................................................................75
7TROUBLESHOOTING....................................................................................................76
7.1 Field repair actions..............................................................................................76
7.2 Inverter fault codes..............................................................................................77
7.2.1 Fault time data record ...............................................................................83
7.2.2 Fault Counter ...........................................................................................84
7.3 Inverter Alarm codes............................................................................................85
8SERVICE ......................................................................................................................86
8.1 DC-bus electrolytic capacitors ..............................................................................86
8.1.1 Re-forming after a long storage period .......................................................86
9GENERAL DRAWINGS ..................................................................................................87

Page 4Service Manual Pro2V070
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1GENERAL
1.1 Technical data
Power class 4004 4005 4009 4012 4016 4022 4031 4038 4045 4061 4072 4087 4105 4140F 4168 4210
Horsepower (Hp) at 460V 2357.5 10 15 20 25 30 40 50 60 75 100 125 150
Output current In (A) 4.3 5.6 912 16 23 31 38 46 61 72 87 105 140 170 205
Max. current 1min (A) 6.5 8.4 13.5 18 24 35 47 57 69 92 108 131 158 210 255 308
Max. current ,Is,2 sec (A) 8.6 10.8 18 24 32 46 62 76 92 122 144 174 210 280 336 410
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
Analog references AIN1: 0 … +10V and AIN2: -10 … +10V; 200k?load?accuracy 0.5%
Encoder feedback EA+/-and EB+/-; 0/24V; 3k?load; floating differential inputs
Control features
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
sN... 100% (sN= 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%
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
Brake slip protection Programmable relay output
Ground fault Provided by electronic circuitry
Overspeed / stall,
Speed difference supervision Independent measurement using 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. Power on >1h in a 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 3mm at 2-9Hz.
Maximum acceleration amplitude 0.5g (5m/s²) at 9-200Hz
Conforms to LV and EMC directives.

Page 5Service Manual Pro2V070
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Type mark coding
XT SERIES can be summarized as "crane motor control systems, 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.
Device name
000-Base Drive (430,440)
000-Pre-engineered Panel (488,489,490,491,492,493,494,496,497,498,499)
x-d (Base drive vector), e (base drive vector with SSU board), s (open loop
vector panel), v (closed loop vector panel)
XT Series
Supply voltage
4380 -500VAC, 50/60Hz
6525 -690VAC, 50/60Hz
Rated Amps
009=9A, 168=168A
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…etc
000 XTx
4
009
TC
0Option Control PCB’s
0Standard (A,B,D)
1Standard with SSU (A,B,C,D)
2Profibus (A,B,D,E)
3Profibus with SSU (A,B,C,D,E)
8Relay (A,B,D,E)
9Relay with SSU (A,B,C,D,E)
000 XTx 4009 TC 0 55 0
Software Revision code
The latest revision may differ 55
Special
0None
LVarnished boards 0

Page 6Service Manual Pro2V070
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1.2 Basic description
XT SERIES have many advantages and offer many new features, when compared to other
inverter-based systems, which might be used in crane applications.
Inverter The inverter in XT SERIES is a crane 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
calculation for several different motor control modes.
Crane user interface All XT SERIES 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 include the brake contactor for disk brakes. XT SERIES
also includes it’s own DC-rectifier.
Electrical braking XT SERIES include a braking transistor, which is dimensioned for every
crane application. For resistor braking XT SERIES are equipped with
external resistor.
Control methods XT SERIES can be controlled by the electronic potentiometer control
with 2-step pushbuttons, the potentiometer control with analog joystick-
type control, the automation control with PLC and radio controls and by
the multistep control with 2-4-step controllers. All these control methods
are available with every XT SERIES.
Limit switch
functions XT SERIES have built-in slowdown and stop limit switch functions for
both running directions.
Speed supervisionXT SERIES include 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. It can also be equipped with SSU.
Protections XT SERIES include a motor thermal protection, which is based on
motor temperature measurement by thermistors placed in the motor
windings. A great number of other protections included in every XT
SERIES are shown in the technical data.

Page 7Service Manual Pro2V070
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1.3 Main components
The main components are:
XT SERIES
A1 Inverter 002-132F
F7 Input supply circuit breaker 007-132F
K7 Brake contactor 002-132F
F71 Circuit breaker for the brake contactor 055-132F
The most important external components are:
R1 External braking resistor unit
M1 Motor
Y1 Mechanical brake
B5 Speed sensor (P-models)
B6 Encoder (N-models)
Thermal sensor for motor protection
Overload protection device (e.g. Premium)
Control devices (switches, pushbuttons, potentiometers etc.)
Limit switches

Page 8Service Manual Pro2V070
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1.4 Functional description
See circuit diagrams for following descriptions of operation.
Operation when
power is switched on ??Limit switches S11, S12, S21 and S22 are assumed to be closed, as well as the emergency stop button ES.
??The control voltage is supplied to A1 control inputs (external
42V…230V control voltage). The main voltage is connected to
inverter power supply and inverter turns on. If the control voltage is
connected to RDY-signal and the fault circuit is OK, inverter is ready
to operate in about 1-2 seconds.
??If either one of the direction signals S1 or S2 is on, the display
shows F6 and running can begin only after the direction signals have
been off for a while.
Normal operation –For the description of the speed reference setting see chapter 1.6
"Control methods".
–Running starts when switch S1 (S2) closes. Closing the contact
ROB2 on A1 energizes K7, which opens the brake. XT SERIES
accelerate according to the acceleration ramp setting to the selected
speed.
–When the switch S1 (S2) opens, XT SERIES stop according to the
deceleration ramp setting and then the brake closes.
–R1 dissipate the regenerated energy during deceleration and
lowering periods. The power supply to R1 is controlled by A1. If the
braking resistor fan(s) are included in external resistor unit, they
start to operate when power is supplied to the braking resistors. The
cooling continues about 4-5 minutes after electrical braking to
ensure that the temperature of the resistors drops below 150?C
(302?F).
Other features –Slowdown limit switches S11 and S21 provide position dependent
frequency limiting.
–Any reason, which opens the contact RDY, stops the operation of
inverter A1.
–In case of overload, motor overheating etc. the hoisting can be
disabled by cutting the direction signal.
–Thermistor relay function, which can be used when needed.
–When the stop limit switch S12 or S22 opens, K7 de-energizes and
the mechanical brake stops the motion.
–Independent speed supervision unit, SSU.
–The speed measurement and supervision can be done either with
encoder, bearing encoder or proximity switch. The measured signals
are square wave pulses. The frequency of the pulses is proportional
to the speed of the motor and if the frequency is too high, overspeed
is detected. If there are no pulses a stall situation is detected. If the
actual speed differs too much from the supply frequency of the
motor, the speed difference supervision stops the motion.
–Proximity switch buffer amplifier amplifies the sensor pulses and
filters out disturbances. The amplifier is located close to the sensor.
–The extended speed range ESR can be used, if the signal FWE (field
weakening enabled) is on. Then it is possible to run up to twice the
nominal speed depending on the application.

Page 9Service Manual Pro2V070
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1.5 Control methods
There are four different control methods (command modes) available. All of them are available
without any changes in the hardware or software. Any single XT SERIES can be controlled either
by a pushbutton controller in EP-mode, by a joystick type controller with a potentiometer located in
the cabin in PO-mode or by a process computer in AU-mode. The only external device needed is a
switch to select the desired control method.
EP Electronic motor potentiometer function.
??Stepless control using a 2-step pushbutton controller.
??EP3 stepless control using a 3-step controller.
PO
Potentiometer control using a joystick type controller.
??Requires a single 15V power supply (included in XT SERIES).
??Any additional amplifier is not needed.
AU
Automation control
??For any control device with an output in the range of 0-10V.
??E.g. radio-controls, process computers.
M
SMultistep control (2-4 steps as standard).
??Requires programmable digital inputs for speed reference steps
(included in XT SERIES).
Command mode
selection The command mode (EP, PO or AU) is selected by the switches CMS
and AP. Normally the selection can be done only when the motion is
stopped (not when running), but in special applications changing the
mode is allowed during run by changing parameter values.
PO-and AU-modes PO-and AU-modes select either of the analog inputs for speed
reference. Both analog inputs can be adjusted similar from 0V to 10V
(radio or PLC-reference) or from 10V to 6.7V (potentiometer). As
default, Ain1 is used in PO-mode and Ain2 is used in AU-mode.
Ain1 / PO Ain1 / PO Ain2 / AU Ain2 / AU Ain1 / PO
DIA3 AP not used AP not used AP not used AP = 0 AP = 1
DIA4 CMS not
used CMS = 0 CMS = 1 CMS = 1 CMS = 1
EP-mode EP-mode selects the AP-button for speed reference. EP step 1 is
command for minimum speed or hold speed. EP step 2 is the
acceleration command.
EP step 1 EP step 2 EP step 1 EP step 2
DIA3 AP = 0 AP = 1 AP = 0 AP = 1
DIA4 CMS not
used CMS not used CMS = 0 CMS = 0

Page 10 Service Manual Pro2V070
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Synchronization If required, two or more XT SERIES can be run in precise
synchronization. A separate synchronization controller is needed for
this. The same speed reference (in EP-or PO-mode) is connected to
every XT SERIES and the correction signal for synchronization is
connected to all XT SERIES to input AIN2+. The speed reference signal
of each XT SERIES can also be modified separately by a PLC.
Synchronization is activated by parameter selection.

Page 11 Service Manual Pro2V070
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Description of the control methods
EP-control requires two 2-step pushbuttons, one
for each direction. The operation is as follows:
??the rest position means standstill (0-position)
??during run the rest position means deceleration
??step one (switch S1 or S2) means hold speed
??when starting, step one means acceleration up to
the minimum speed
??step two (switch AP) means acceleration (up to
the maximum speed if desired)
??at the maximum speed step two means hold
speed, because the maximum speed cannot be
exceeded
Pushbutton 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
MS-control requires a 2-4-step controller. The
operation is as follows:
??each step has its own frequency
??the frequencies are freely selectable
??when controller is set to a certain step, the speed
changes to equal value
speed
controller
position
up / fwd
down / rev
time
speed
controller
position
MS-mode

Page 12 Service Manual Pro2V070
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1.6 Mechanical brake control
The brake is controlled so that during starting, the motor first generates torque and after that the
brake is opened. The same applies for stopping; while the brake is being closed, the motor still
generates torque. During a direction change, the brake is kept open all the time. XT SERIES
decelerate the motor to a stop according to the set deceleration time when the run command is
switched off, so the brake is used only as a holding brake. This way brake wear is minimized. Only
if a failure occurs or the emergency stop button is pushed, the brake closes immediately stopping
the motor and the load.
The motors of CXT-hoists and SM-trolleys have an electromechanical disk brake. The disk brake is
opened and kept open during run by DC-voltage. When there is no voltage present the brake is
closed and also kept closed by spring force.
2-phase AC
XT SERIES models may include an AC-supply from two phases for the
brake control. XT SERIES controls this line and it is protected by an
adjustable circuit breaker. An external rectifier may be included to
rectify the AC-voltage to DC-voltage for DC brake coils.
3-phase AC
XT SERIES models may include a 3-phase AC-supply for the brake
control. XT SERIES control this line and it is protected by an adjustable
circuit breaker.

Page 13 Service Manual Pro2V070
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1.7 Motor control modes
Open loop
XT SERIES have a built-in motor model, which calculates -one thousand times in a second -the
values of the real motor. The input data needed for the calculation is the instantaneous value of
the motor voltage from the ASIC and the measured motor current. Motor magnetic flux and shaft
torque are calculated in the motor model based on the nameplate data of the motor.
Open loop
Vector control Speed
ref InverterAsic
Current
Vector
calculation
Speed
Control
Torque
Flux
ref
M
3~
Frequency control
Open loop (mode 0) In frequency control mode of Open Loop, the motor frequency follows the
frequency reference signal. The actual rotating speed depends on load and is
equal to the slip below or above the output frequency. Even with frequency
control, the vector calculation is used to keep the magnetization at a correct
level.
Current control
Open Loop (mode 1) In current control mode of Open Loop, the motor follows the frequency
reference signal. The motor is current controlled in small frequencies
(typically <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 even a simpler
configuration than the open loop vector control. This is because an additional input data, as the
signal from the incremental encoder is available. This measurement of the function of the actual
motor is used as feedback to the motor model calculation and allows possibilities for additional
checking of the motor control.
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 the speed control mode of Closed Loop, the motor speed follows the speed
reference signal. XT SERIES adjust 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 conditions. With the closed
loop speed control it is even possible to reach zero speed with full torque.
Torque control
Closed loop (mode 4) In torque control mode, the shaft torque is kept equal to the reference signal.
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.

Page 14 Service Manual Pro2V070
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1.8 EMC
The shortening "EMC" stands for the Electro Magnetic Compatibility. According to the EMC
directive "the apparatus shall be so constructed that:
a) The electromagnetic disturbance it generates does not exceed a level allowing other
apparatus to operate as intended
b) The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to
enable it to operate as intended."
Technical
construction file The technical construction file describes how the frequency converters
have been constructed to comply with the directive and standard
requirements.
Declaration of
conformity With the declaration of conformity the manufacturer informs that device
is manufactured to fulfill required EMC standards.
CE-mark The CE marking is a declaration by a manufacturer or importer located
in the European Economic Area that a product complies with the safety
and health requirements of the directive in question. The manufacturer
demonstrates for the authorities that the product complies with the
safety requirements within the EU.
Environments Immunity and emission requirements are divided in two levels in the
product standard according to the environments.
PDS
PDS
First environment means environment that includes domestic premises
and also establishments directly connected to a low-voltage power
supply network.
XT SERIES are not intended to be used on a low-voltage public
network, which supplies domestic premises. Radio frequency
interference is expected if used on such a network.
Second environment means environment that includes all
establishments other than those directly connected a low-voltage power
supply network.
Power drive system (PDS) means a system consisting of power and
control equipment, including XT SERIES.
1.8.1 Fulfilled EMC-standards
Immunity XT SERIES fulfill the immunity requirements defined in the EN 61800-3
Amendment 11 (2000) for the second environment.
Emissions XT SERIES fulfill the emission requirements of the EN 61800-3 A11
2000 for the second environment.

Page 15 Service Manual Pro2V070
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Immunity level of
second environment
Emission limit of
second environment
Emission limit of
first environment
Typical emission
of D2H/D2C
Safety margin
Interference
level
Frequency

Page 16 Service Manual Pro2V070
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2INSTALLATION
2.1 Cooling
The needs of cooling arrangements for the XT SERIES vary by application. The actual thermal
loading of the enclosure has to be estimated based on the loading conditions and duty cycles. The
power losses of XT SERIES are listed in the below table for each power rating. In most cases, XT
SERIES models up to 132F do not require any special cooling arrangements as the main part of
the losses is fed outside the cubicle in standard installations. Cooling for models, which are
installed in totally closed cubicles, is required to be checked case by case.
Through panel mounted Totally enclosed cubicle
Model ED40 ED60 ED100 ED40 ED60 ED100
002F 21 24 29 67 92 141
003F 20 22 25 53 70 104
004F 21 23 28 64 87 132
005F 24 28 36 96 134 211
007F 25 30 39 116 160 248
011F 31 39 54 176 250 398
015F 30 37 51 177 246 383
018F 38 49 71 256 364 581
022F 41 54 79 289 413 662
030F 34 43 60 230 318 493
037F 43 57 83 322 456 724
045F 53 71 107 415 596 957
055F 54 72 108 570 749 1108
075F 73 101 156 763 1039 1591
090F 89 125 197 927 1284 1999
110F 73 101 157 1013 1291 1845
132F 89 125 196 1170 1526 2237
Note! The power losses given above do not include the power fed to the braking
resistors.
2.2 Power cabling
Shielded
motor cable In crane application, XT SERIES fulfills EN61800-3/A11 (IEC 1800-3) second
environment radiated emission requirements without shielded motor cable.
However shielded motor cable is recommended to use in fixed installations,
especially in buildings.
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.
Shielded motor cable is essential to use if 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
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.

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Cable
selection Cabling for XT SERIES 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 400V supply).
The table below is based on rated continuous current and ambient temperature
+40?C (104?F). A higher ambient temperature may require increased cable sizes.
If the actual load current is below XT SERIES continuous current, then the fuses
and the supply cable may be dimensioned according to the load current.
Power class 002 004 005 007 011 015 018 022
Continuous current ICONT A5.6 912 16 23 31 38 46
Fuse/MSP A6.2
511.25
15 20 27.
538.75
47.
556.25
Max motor cable
length m50 50 50 50 50 50 50 50
Ft 160 160 160 160 160 160 160 160
Motor cable
104o
FAWG
14 14 14 14 14 10 88
Braking resistor cable
104o
FAWG
14 14 14 14 14 14 10 8
Power class 030 037 045 055 075 090 110 132
Continuous current ICONT A61 72 87 105 140 170 205 245
Fuse A80 90 110 125 175 225 250 300
Max motor cable
length m50 50 75 75 75 75 100 100
Ft 160 160 240 240 240 240 325 325
Motor cable
104o
FAWG
65431/0 2/0 3/0 3/0
Braking resistor cable
104o
FAWG
64321/0 1/0 2/0 3/0
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 XT SERIES protects both the supply and the motor
cables. The fuses of the supply provide the short circuit protection.

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Drivecon Inc. reserves the right to alter or amend the above information without notice 21.12.2004 • XT SERIESCSM55BEN
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
AlI
pUF
? ?
?
?
?
243 15 ..
where lis the cable length (m)
IFis the motor current (A) at shaft power PF
pis the allowed voltage drop in %
Uis the nominal motor voltage
Note! All control cables must be placed as far from the motor and braking resistor
cables as possible.

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Drivecon Inc. reserves the right to alter or amend the above information without notice 21.12.2004 • XT SERIESCSM55BEN
2.3 Control wiring
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
the 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.
Reference signals Shielded round cables must be used for analog reference signals. The
shield is to be grounded only at XT SERIES (not at the other end of the
cable).
Sensor bearing The cable for the sensor bearings must be shielded round cable and
grounded at both ends.
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 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 connected to minimize disturbances.
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 coupling capacitances and
inductances.
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 maintain its integrity as much as possible. Spare
conductors should be grounded in the both ends.