Drivecon XR Series User manual

XR SERIES DAHSM32HA
Pages 123 (+ cover sheet)
Service Manual
XR SERIES

XR SERIES
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Drivecon, Inc. reserves the right to alter or amend the above information without notice 1.10.1999 • DAHSM32HA
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DRIVECON, INC.
CAUTION
1. Before starting read carefully instructions and this table.
2. Verify all connections are according to drawings.
3. Verify motor supply is connected correctly, wrong connection will
destroy the inverter.
4. Verify internal voltage selections of device are correct.
5. Check device cover is properly installed and all ventilation holes are
clear and uncovered.
6. Check that hot air coming from brake resistors does not cause any
danger.
7. High voltages are present in this device. Do not make any inspections
unless the supply has been disconnected by main switch. Before
opening the device cover, wait at least 5 minutes after the display
lamps turn off.
8. Insulation resistance test with a megger requires special precautions.
9. Do not make any measurements inside the device when it is
connected to main supply.
10. Do not touch the IC-circuits on the circuit boards. Static voltage
discharge may destroy the components.
11. It is forbidden to use radiophones and portable phones near this
device with the doors open.
12. All the doors and covers must be closed during crane in operation.

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CONTENTS
1DESCRIPTION OF XR SERIES HOIST..........................................................................4
1.1 Functional description ....................................................................................... 6
1.2 Motor control modes..........................................................................................7
1.3 Control methods (= command modes) ................................................................8
1.4 Mechanical brake control................................................................................. 12
2PROGRAMMING OF XR SERIES HOIST..................................................................... 13
2.1 LED display panel........................................................................................... 13
2.1.1 How to use the LED display keyboard............................................................... 13
2.1.2 Panel operation .............................................................................................. 14
2.1.3 Monitoring page.............................................................................................. 15
2.1.4 Parameter page.............................................................................................. 17
2.1.5 Reference page .............................................................................................. 17
2.1.6 Programmable pushbutton page....................................................................... 18
2.1.7 Fault history page........................................................................................... 19
2.1.8 Active fault display.......................................................................................... 19
2.1.9 Active warning display..................................................................................... 20
2.2 Graphical display panel................................................................................... 21
2.2.1 How to use the graphical display keyboard........................................................ 22
2.2.2 Page selection page........................................................................................ 22
2.2.3 Monitoring page.............................................................................................. 22
2.2.4 Operating page............................................................................................... 23
2.2.5 Parameter page.............................................................................................. 23
2.2.6 Actual values page.......................................................................................... 24
2.2.7 Trend page..................................................................................................... 24
2.2.8 Trend menu page............................................................................................ 24
2.2.9 Active faults page........................................................................................... 25
2.2.10 Fault history page ......................................................................................... 25
2.2.11 Contrast page ............................................................................................... 25
2.2.12 Info/Files page.............................................................................................. 26
2.3 Description of parameters................................................................................ 27
2.3.1 Parameter group 1; Modified parameters.......................................................... 27
2.3.2 Parameter group 2; Basic parameters............................................................... 27
2.3.3 Parameter group 3; Input signal parameters...................................................... 28
2.3.4 Parameter group 4; Output signal parameters................................................... 34
2.3.5 Parameter group 5; Drive control parameters.................................................... 37
2.3.6 Parameter group 6; Motor parameter set 1........................................................ 41
2.3.7 Parameter group 7; Open loop 1 ...................................................................... 46
2.3.8 Parameter group 8; Closed loop 1.................................................................... 49
2.3.9 Parameter group 9; Motor parameter set 2........................................................ 50
2.3.10 Parameter group 10; Open loop 2................................................................... 50
2.3.11 Parameter group 11; Closed loop 2 ................................................................ 50
2.3.12 Parameter group 12; Intelligent ramps............................................................ 51
2.3.13 Parameter group 13; Profibus diagnostic parameters....................................... 55
2.3.14 Parameter group 14; Profibus control ............................................................. 57
2.3.15 Parameter group 15; Protection parameters.................................................... 59
2.3.16 Parameter group 0; Application parameters..................................................... 61
3START-UP PROCEDURE........................................................................................... 62
3.1 Visual checks ................................................................................................. 63
3.2 Checks before the first test run........................................................................ 63
3.3 Test run without load....................................................................................... 64
3.4 Test run with load ........................................................................................... 64
3.5 After the test run............................................................................................. 64
4SERVICE .................................................................................................................. 65
5TROUBLESHOOTING ................................................................................................ 66
5.1 Inverter fault codes......................................................................................... 67
5.2 Field repair actions ......................................................................................... 77

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DRIVECON, INC.
Appendix A1 Technical data......................................................................................... 78
Appendix A2 Inverter................................................................................................... 79
Appendix A3 XR Board ................................................................................................ 87
Appendix A4 NOVA ..................................................................................................... 89
Appendix A5 KAE234 - proximity switch buffer amplifier ................................................ 92
Appendix A6 Speed supervision sensor......................................................................... 93
Appendix A7 Encoder connection.................................................................................. 95
Appendix A8 ESD141................................................................................................... 98
Appendix A9 Potentiometer specification ...................................................................... 99
Appendix A10 Description of terminals..........................................................................100
Appendix A11 Signal connections .................................................................................101
Appendix A12 Wiring harness connections.....................................................................103
Appendix A13 Closed loop tuning..................................................................................104
Appendix A14 Parameter defaults and lock levels..........................................................110
Appendix A15 Specialities of profibus models................................................................113
Appendix A16 Specialities of "No braking" models .........................................................114
Appendix A17 XR Series V 4.0 F-A-x-x-x-A....................................................................115
Appendix A18 Alterations .............................................................................................117
Appendix A19 Replacing old XR Series versions............................................................118
Appendix A20 Spare Parts lists.....................................................................................119
Appendix A24 Commission table...................................................................................122

XRSeries Variable Frequency Drives Product Code
In order to specify the correct part number to suit your needs please refer to the type code
shown below. XRd 4 009 0 xx V
d = Base drive scalar
e = Base drive vector
s = Scalar panel
v = Vector panel
r = Regen base drive
i = Inverter base drive
w = Water cooled vector base drive
Voltage:
4 = 380-500
6 = 525-690
Rated amps: ie = 009 = 9A, 168 = 168A
Family type
Option PCB’s:
0,1,2,3,4,5,6,7,8,9
Software revision
Special option:
V = varnished
Drivecon
MOTOR DRIVES AND CONTROLS
820 Lakeside Drive - Gurnee, IL. 60031
PH: 847-855-9150 FAX: [phone]
www.drivecon.com
Consult factory for any inquiries.

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DRIVECON, INC.
Advantages of stepless speed control
− improved positioning accuracy due to a low minimum speed
− reduced mechanical stresses due to soft start and stop
− reduced brake wear due to electric braking; the mechanical brake is used only as a holding
brake
− easier to use for inexperienced operators; the less experienced the operator is, the slower
he/she can drive to avoid damaging the load. With XR Series the productivity of the crane can
be improved
− both a very low creeping speed and a very high main speed can be utilized
Advantages of frequency control compared to other stepless speed control
systems
− squirrel cage motor; inexpensive, minimal need for maintenance, simple and robust
construction, good tolerance to bad ambient conditions, small size, low weight
− selectable maximum frequency and speed; not dependent on the supply voltage
− a wide speed control range; minimal driving time restrictions at low speeds (minimal motor
heating)
− minimum amount of external components; no rotor resistors, no tachometer
− good efficiency and power factor
− low starting current; proportional to the desired acceleration rate
Advantages of XR Series compared to other inverter based systems in hoisting
motion
All the crane specific functions are included as standard features
– safety circuitry
– crane specific user interface
– electric braking including resistors
– limit switch functions
– the area between the slowdown and the end limit switches can be fully utilized by using the
distance proportional function, which limits the speed proportionally to the travelled distance
– motor thermal protection; thermistor relay function
– mechanical construction specially designed for cranes (a specific XR Series cubicle, which
usually is placed in the bridge cubicle row)

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1.1 Functional description
Operation when power is connected to XR Series
− Limit switches S11, S12, S21 and S22 are assumed to be closed, as well as the emergency
stop button ES.
− If F7 is closed, as it normally is, the control voltage transformer T1 supplies the 48V voltage to
A3 control inputs (external 48V, 115V or 230V voltage can be used too).The internal 48V
control voltage is connected to EST-signal and the XR Series line contactor K1 is energized (in
models 55F-800F, 30J-45J, 90K-630K, via the auxiliary contactor K01). After the fault circuit is
OK and A4 contact is closed, XR Series is ready to operate in about 1-2 seconds.
− If either of the direction signals S1 or S2 is on, the XR Series display shows F52 and driving
can begin only after the direction signals have been off for a while.
Normal operation
– For the description of the speed reference setting see chapters 1.3 "Control methods" and 2.3
"Description of parameters".
– Hoisting (lowering) starts when switch S1 (S2) closes. Closing the contact 22-23 on A1
energizes K7 which opens the brake (in models 55F-800F, 30K-630K the brake can be
controlled also by K71). XR Series accelerates according to the acceleration ramp setting to
the selected speed.
– When the switch S1 (S2) opens XR Series stops according to the deceleration ramp setting
and the brake closes.
– R1-R4 dissipate the regenerated energy during deceleration and lowering periods. The power
supply to R1-R4 is controlled by A1. If the braking resistor fan(s) are included in the XR
Series, 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. See
description of parameter P5.2 in section 2.3.5.
– Any reason which causes K1 to de-energize (like opening of contact ES) switches power off
from inverter A1.
– In case of overload, motor overheating etc. the hoisting can be disabled by terminals X1:13-
14, which are jumped if any protection is not used.
– Thermistor relay function, which can be used when needed.
– When the stop limit switch S12 or S22 opens, K7 (and K71 in models 55F-800F, 30K-630K)
de-energizes and the mechanical brake stops the motion.
– Independent speed supervision unit, NOVA
– The output of speed supervision sensor B5 is 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 A5 amplifies the sensor pulses and filters out disturbances.
The amplifier is located close to the sensor.
– If XR Series has been equipped with an encoder option, the encoder B6 can also be used for
speed supervision. That is done by connecting XR Series E64 output signal (encoder pulses
divided by 64) to the PS input instead of the speed sensor B5.
– The extended speed range ESR can be used, if the signal FWE (field-weakening enabled) is
on. Then it is possible to drive up to twice the nominal speed depending on the application.

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1.2 Motor control modes
XR Series has several motor control modes for open loop and closed loop vector control:
− Frequency control, open loop
− Speed control, open loop and closed loop
− Torque control, closed loop
The most used modes for XR Series are open loop speed control (for XL-motors) and closed loop
speed control (for all motors).
In XR Series open loop speed control (P-models) the actual speed depends on the load. The
lowest possible driving frequency is nominal slip plus a small margin. The speed accuracy of
open loop vector control is 1% of nominal speed at speed range 10 ... 100% and 1/3 of motor
nominal slip at speed below 10%.
In XR Series closed loop speed control (N-models) the actual speed is equal to the reference.
The speed accuracy of closed loop vector control is 0.01% of nominal speed.
In speed control mode the motor speed follows the speed reference signal. XR Series adjusts the
motor frequency and with this function compensates the load-dependent slip. This method is most
suitable for hoisting applications. The slip compensation keeps the actual shaft speed constant
and independent of loading conditions. With open loop speed control, the applicable minimum
speed is about equal to motor rated slip. With the closed loop speed control it is even possible to
reach zero speed with full torque.
The torque control is only used for special applications such as tandem drive and mechanical
grab.

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1.3 Control methods (= command modes)
There are four different control methods (command modes) available:
1 EP − Electronic motor potentiometer function.
− stepless control using a 2-step pushbutton controller.
− EP3 stepless control using a 3-step controller.
2 PO − Potentiometer control using a joystick type controller.
− requires a single 15V power supply (included in XR Series).
− any additional amplifier is not needed.
− see also description of parameters P3.6 - P3.9 and potentiometer specification
(Appendix A9).
3 AU − Automation control for any control device with an output in the range of 0-10V.
− e.g. radio-controls, process computers.
− see also description of parameters P3.11 - P3.14.
4 MS − Multistep control (2-4 steps as standard)
− up to 8 steps available (see description of parameters P5.9 - P5.16).
All four control methods are available without any changes in the hardware or software. Any
single XR Series can be controlled (for example) 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.
If required, two or more XR Seriess can be driven in precise synchronization. A separate
synchronization controller is needed for this. The same speed reference (in EP- or PO-mode) is
connected to all XR Seriess and the correction signal for synchronization is connected to all XR
Seriess depending of the model to the AS-input (P-models) or to the KR-input (N-models). The
speed reference signal of each XR Series can also be modified separately by a PLC.
Synchronization is activated by parameter selection.
Multistep control is usually done with the MS-control function. An other method for multistep is to
use AU-control and an additional PC-board KAE165.
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.
Command mode selection
Mode CMS AP
AU closed open
PO closed closed
EP open closed at 2. step (acceleration signal)
MS selected by parameters

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Description of the control methods
In EP-control there are 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
down
time
EP-mode
In EP3-control there is 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
Pushbutton position
rest = stop
step 1 = minimum speed
step 2 =hold speed
step 3 = acceleration
speed
pushbutton
position
up
down
time
EP3-mode
The operation in PO-control 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
The operation in AU-control 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
down
speed speed
controller
position
time
potentiometer reference (controller position)
or auxiliary reference
PO- and AU-modes
MS-control has a 2-4-step controller (up to 8 speed
steps available depending on 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
down
time
speed
controller
position
MS-mode
More information on using the different control methods is given in Section 2.3 "Description of
parameters". More information about the PO-control potentiometer function is given in Appendix
A9 "Potentiometer specification".