Drivecon XT Series User manual

Service Manual
Rev 5.6B5 with software Pro2V080
and Pro2V081
XT SERIES
Service Manual
820 Lakeside Drive – Gurnee, IL 60031
Phone: [phone]
Fax: [phone]
www.drivecon.com
This document and the information contained herein, is the exclusive property of
Drivecon, Inc. 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, Inc.
Copyright © 006 Drivecon, Inc. All rights reserved.

Page 1
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
CONTENTS
1GENERAL.......................................................................................................................4
1.1 Technical data ......................................................................................................4
1.2 Type mark coding..................................................................................................5
1.3 Basic description...................................................................................................6
1.4 Functional description............................................................................................7
1.5 Control methods....................................................................................................8
1.6 Mechanical brake control.....................................................................................10
1.7 Motor control modes............................................................................................10
1.8 EMC................................................................................................................... 11
1.8.1 Fulfilled EMC-standards............................................................................ 12
2INSTALLATION.............................................................................................................13
2.1 Cooling............................................................................................................... 13
2.2 Power cabling ..................................................................................................... 13
2.3 Control wiring...................................................................................................... 15
2.4 EMC compatible grounding ..................................................................................16
3START-UP PROCEDURE .............................................................................................. 17
3.1 Visual checks...................................................................................................... 17
3.2 Checks before the first test run ............................................................................17
3.3 Test run without load...........................................................................................18
3.4 Test run with load................................................................................................18
3.5 After the test run and autotuning ..........................................................................18
4PARAMETER ADJUSTMENTS .......................................................................................19
4.1 Control keypad operation.....................................................................................19
4.1.1 Navigation on the control keypad............................................................... 20
4.1.2 Value line editing...................................................................................... 20
4.1.3 Passwords................................................................................................21
4.1.4 Special button functions and shortcuts.......................................................21
4.1.5 Monitoring................................................................................................ 22
4.2 Input selections................................................................................................... 23
4.3 Speed supervision settings .................................................................................. 24
4.3.1 Functional test run for SSU .......................................................................26
4.4 Open Loop motor parameter adjustments.............................................................. 27
4.4.1 Open Loop speed control for hoisting......................................................... 27
4.4.2 Open Loop motor parameters for traveling ................................................. 27
4.4.3 Open Loop autotuning for traveling, frequency control................................. 28
4.4.4 Open Loop manual tuning for traveling....................................................... 28
4.4.5 Open Loop manual tuning for traveling, frequency control ........................... 29
4.4.6 Open Loop manual tuning for traveling, current control ............................... 29
4.5 Closed Loop motor parameter adjustments............................................................ 30
4.5.1 Closed Loop rated motor parameters ......................................................... 30
4.5.2 Closed Loop autotuning, speed control....................................................... 31
4.5.3 Closed Loop manual tuning for hoisting, speed control ................................ 34
4.6 Brake Slip Feature……………………………………………………………………………….37
4.6.1 Description of brake slip feature………………………………………...…………..37
4.6.2 Activation of brake slip feature……………………………..……………..………..38
4.6.3 Brake Slip Feature Field Testing Procedure…………………………..……….….38
4.6.4 What to do in case of brake slip……………………………………………………..39
4.6.5 Service on hoist motor/encoder/brake with Brake Slip feature active………...40
5PARAMETER DESCRIPTIONS....................................................................................... 41

Page 3
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
6COMPONENTS.............................................................................................................54
6.1 Inverter .............................................................................................................. 54
6.1.1 Power supply unit (PSU) ...........................................................................56
6.1.2 Control unit (CSU)....................................................................................56
6.1.3 Basic I/O board (Slot A)............................................................................57
6.1.4 Relay / Thermistor board (Slot B) ..............................................................58
6.1.5 SSU Speed Supervision board (Slot C) ...................................................... 58
6.1.6 I/O Extension board (Slot D)......................................................................59
6.1.7 Relay Extension board (Slot E)..................................................................59
6.1.8 Profibus board (Slot E) .............................................................................60
6.2 Reference potentiometer......................................................................................61
6.3 Speed sensors ....................................................................................................62
6.3.1 Encoder................................................................................................... 62
6.3.2 Bearing Sensor.........................................................................................63
6.3.3 Proximity switch.......................................................................................64
6.3.4 Buffer amplifier KAE234 ........................................................................... 65
6.4 Brake controllers.................................................................................................66
6.4.1 REC12-690+DC........................................................................................ 66
6.4.2 ESD141................................................................................................... 66
7TROUBLESHOOTING.................................................................................................... 67
7.1 Field repair actions..............................................................................................67
7.2 Inverter fault codes ............................................................................................. 68
7.2.1 Fault time data record...............................................................................73
7.2.2 Fault Counter........................................................................................... 73
7.3 Inverter Alarm codes........................................................................................... 74
8SERVICE......................................................................................................................75
8.1 DC-bus electrolytic capacitors..............................................................................75
8.1.1 Re-forming after a long storage period....................................................... 75
9DRAWINGS..................................................................................................................76

Page 4
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
1 GENERAL
1.1 Technical data
Overloadability 1.5 x In, 1min/10min; 2.0 x In, 2s/20s
Max. output voltage Equal to supply voltage
Supply
Supply voltage 460-series 380-500VAC, 575-series 525-690VAC
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; 200kΩload;accuracy 0.5%
Encoder feedback EA+/- and EB+/-; 0/24V; 3kΩload; 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% programmable
Braking torque 150%
Protections
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 333V (460-series), 460V (575-series)
Overvoltage protection Fault is detected if DC voltage exceeds 911V (460-series), 1200V (575-series)
Momentary power loss Immediate fault stop
Inverter overtemperature Temperature sensor on the heat sink
Mechanical brake Brake contactor control relay
Braking transistor Electronic supervision for the braking chopper and for the braking resistor
Brake 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
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 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
Conforms to LV and EMC directives (optional).
Power Class (460-series) 4004 4005
4009 4012 4016 4022 4031 4038 4045 4061 4072 4087 4105 4140 4168 4210 4245 4300 4385 4460 4590 4650
Frame Size Fr4 Fr4
Fr4 Fr4 Fr5 Fr5 Fr6 Fr6 Fr6 Fr7 Fr7 Fr7 Fr8 Fr8 Fr8 Fr9 Fr9 Fr10 Fr10 Fr10 Fr11 Fr11
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)
5005 5007 5010 5013 5018 5022 5027 5034 5041 5052 5062 5080 5100 5125 5144 5170
Frame Size Fr6 Fr6
Fr6 Fr6 Fr6 Fr6 Fr6 Fr7 Fr7 Fr8 Fr8 Fr8 Fr9 Fr9 Fr9 Fr9
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

Page 5
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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.
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)
Supply voltage
4 380 - 500VAC, 50/60Hz
5 525 - 690VAC, 50/60Hz
Power class current handling type code
See technical specifications
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
000 XTx
4
009
TC
56 Software Revision code
The latest revision may differ
000 XTx 4 009 TC 56 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
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 6
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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
d
issipate 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 a
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 7
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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 and inverter
will power up. If the control voltage ok and the ready circuit has all
of its 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, 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 8
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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
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.

Page 9
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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
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

Page 10
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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.
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.

Page 11
Service Manual
Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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 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.

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Environments Immunity and emission requirements are divided in two levels in the
product standard according to the environments.
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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Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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.
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.

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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 ICONT A 4.5 5.5 9 12 16 22 31 38
Motor cable 104oF AWG 14 14 14 14 14 14 12 10
Braking resistor cable for
hoist
CMAA Class D SRML Cable 104oF
AWG 14 14 14 14 14 14 14 14
Braking resistor cable for
travel
CMAA Class D SRML Cable 104oF
AWG 14 14 14 14 14 14 14 14
Power class 4045
4061 4072 4087 4105 4140 4168 4210
Continuous current ICONT A 45 61 72 87 105 140 168 210
Motor cable 104oF AWG 8 6 6 4 2 1 1/0 2/0
Braking resistor cable for
hoist
CMAA Class D SRML Cable 104oF
AWG 10 8 6 6 4 1/0 1/0 1/0
Braking resistor cable for
travel
CMAA Class D SRML Cable 104oF
AWG 10 8 6 6 4 2 2 2
Power class 5005
5007 5010 5013 5018 5022 5027 5034
Continuous current ICONT A 5.5 7.5 10 13.5 18 22 27 34
Motor cable 104oF AWG 14 14 14 14 14 10 10 8
Braking resistor cable for
hoist
CMAA Class D SRML Cable 104oF
AWG 14 14 14 14 14 14 14 10
Braking resistor cable for
travel
CMAA Class D SRML Cable 104oF
AWG 14 14 14 14 14 14 14 12
Power class 5041
5052 5062 5080 5100 5125 5144 5170
Continuous current ICONT A 41 52 62 80 100 125 144 170
Motor cable 104oF AWG 8 4 4 2 2 2/0 2/0 3/0
Braking resistor cable for
hoist
CMAA Class D SRML Cable 104oF
AWG 8 6 6 4 2 1 1/0 2/0
Braking resistor cable for
travel
CMAA Class D SRML Cable 104oF
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 Drivecon.

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Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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
effects 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.
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.

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Pro2V081
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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.

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Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
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.

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- Check to make sure the parameters are properly set. Take notes of all of the parameter
adjustments that were necessary on the parameter list supplied with the drive; write down in
the parameter list all the values that have been changed.
3.3 Test run without load
- Reference chapter 4.4 Open Loop motor parameter adjustments and chapter 4.5 Closed Loop
motor parameter adjustments.
- Make sure that movement will not cause any danger to the environment or to the crane itself.
Avoid running close to the limit areas.
- Check the limit switches manually if possible.
- Check the run commands on the keypad display and correct the motor rotating direction. The
arrow rotates clockwise if S1 (fwd/up) is applied, and counter-clockwise if S2 (rev/down) is
applied.
- Check the function of the speed sensor, see chapter “Speed sensors”
- Check the function of the speed supervision circuit. See "Functional test run for SSU".
- Run forward (upwards) at minimum speed for 5 to 10 seconds. Accelerate to full speed. Run 5
to 10 seconds. Stop. Repeat the same in the reverse (down) direction. Check the frequency
display to make sure that the frequency changes through the whole operational frequency
range from the minimum to the nominal speed.
- Check the motor operation (acceleration, deceleration and braking): accelerate to full speed
forward (up), change to full speed reverse (down) and full speed forward (up) again and stop.
- Check the limit switch functions: run forward (up) slowly and check the slowdown and the stop
limit switch operations. Re-check using full speed. Repeat the same check for the reverse
(down) direction.
- If the optional ESR is used, check the maximum frequency.
- When all functionality is verified to be correct, autotuning needs to be performed.
- See chapter 4.4.3 for open loop autotuning instructions for Traverse motions.
- See chapter 4.5.2 for closed loop autotuning instructions for Hoist motions with an encoder.
3.4 Test run with load
- See also chapter 4.4 Open Loop motor parameter adjustments and chapter 4.5 Closed Loop
motor parameter adjustments
- Note, three loads are required:
- Nominal load (100%) for normal operation.
- Limited load for ESR (optional).
- An adequate extra load for dynamic overload testing and to test the ESR load limit.
- Make sure that movement will not cause any danger to the environment or to the crane itself.
- If the optional extended speed range (ESR) is used, check that the load limit is correctly set
and hoisting with bigger loads is prevented.
- Run in both directions at minimum and maximum speeds.
- If the fan tube resistor unit is included, check that the fan(s) starts to blow when running down
with nominal load and continues to blow for about 4-5 minutes after stopping.
3.5 After the test run and autotuning
- Record all the parameter value changes in the parameter list.
- Make sure all remarks and setting values are recorded.
- Copy all parameters up to keypad memory at parameter 6.3.2.
- Save user parameters in Control Unit at parameter 4.1.2.

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Pro2V080
Pro2V081
Drivecon reserves the right to alter or amend the above information without notice12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 software
4 PARAMETER ADJUSTMENTS
4.1 Control keypad operation
Drive status indications :
RUN Motor is running
Motor rotation direction
STOP Inverter is not running
READY OK circuit is active
ALARM
Active warning
FAULT
Active fault
Control place indications :
I/O term Terminals are the selected control place
Keypad Control keypad is the selected control place
Bus/Comm Control through Profibus is selected
Text lines :
Line 1 Location indication (parameter number)
Line 2 Description line (parameter name)
Line 3 Value line (parameter value)
Status LEDs :
ready green Illuminates the AC-supply is on
run green Illuminates during run
KeypadI/O term
READY FAULTSTOPRUN ALARM
Bus/Comm
P3.4.1.1.
Motor Nom Volt
400 V
START
STOP
enter
select
reset
ready run fault
fault red Illuminates due to a fault
Button descriptions – also see section 4.1.4 for keypad shortcuts:
reset Reset active faults START
Starts the motor if the keypad is the
active control location
select Switch between two latest
displays STOP
Stops the motor if the keypad is the
active control location
enter Confirmation of selections
Browse up the menus
Increase values
Move to previous menu level
Move cursor left
Exit edit mode
Browse down the menus
Decrease values
Move to next menu level
Move cursor right
Enter edit mode
Warning! Running via keypad can cause a hazardous situation. Keypad control must not
be used.