Drivecon XT Series User manual

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
Owner’s Manual
Drivecon XT Series
Owner’s Manual
820 Lakeside Drive - Gurnee, IL 60031
Phone: [phone] Fax: [phone]
1-800-DRIVCON (374-8266)
www.drivecon.com Email: [e-mail]
Revision 5.4D Pro1V050
6-01-04

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
Table of Contents
CHAPTER A - SAFETY
Forward A-1
Examination before installation and Purchase History A-2
Safety Precautions A-3
Understanding and selecting the correct part number A-7
CHAPTER B - TECHNICAL DATA
Introduction B-1
Technical Data B-2
CHAPTER C - INSTALLATION INSTRUCTIONS
Installation instructions C-1
Stripping length of motor and main cables C-2
Cooling C-3
Inverter Dimensions C-5
CHAPTER D - WIRING AND SIZING INFORMATION
Cable installation and the UL standards D-1
Cable and Motor insulation checks D-1
Cable and Fuse sizing D-2
Frame sizes and installation of cables D-3
Control unit D-7
I/O and Relay Boards D-8
Digital Input Connections D-13
XTD-4000 Series Open Loop Traverse Wiring Diagram D-14
XTD-4000 Series Closed Loop Traverse Wiring Diagram D-15
XTD-4000 Series Open Loop Load Brake Hoist Wiring Diagram D-16
XTD-4000 Series Closed Loop Hoist Wiring Diagram D-17
CHAPTER 1 - DESCRIPTION
Functional Discription 1
Control Methods 2-3
Mechanical Brake Control 4
Motor Control Modes 5
EMC 6
CHAPTER 2 – START-UP PROCEDURE
Checks 7
Test Run 8
CHAPTER 3 – PARAMETER ADJUSTMENTS
Control Keypad 9-10
Monitoring 11
Parameter Groups 12
CHAPTER 4 – COMPONENTS
Spare Parts List 13
Spare Parts List 14
Fault Codes 15-19
Fault Counter 20
CHAPTER 5 – SERVICE
Service 21

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
CHAPTER A – SAFETY
Foreward
To fully employ all functions of the inverter, and to ensure the safety of users, please read through
this operating manual in detail. Should you have any further inquiry, contact your local distributor or
Drivecon at 1-800-374-8266 toll free or 847- 855-9150.
Precaution: Inverter is a power electronic device. For safety reason, please note paragraphs with
“WARNING” or “CAUTION” heading.
WARNING!: Personal injury may result with improper operation.
CAUTION!: The inverter or mechanical system may be damaged by improper operation.
WARNING!
• Do not touch the PCB or components on the PCB while power is on or immediately after
turning off the power. Wait for the charging indicator light to extinguish.
• Do not attempt to wire circuitry while power is on. Do not attempt to examine thecomponents
and signals on the PCB while the inverter is running or power is on.
• Do not disassemble or modify internal circuitry, wiring, or components of the inverter.
• The grounding terminal of the inverter must be grounded properly according to local codes
orNEC standards.
CAUTION!
• Do not attempt to conduct dielectric strength test to internal components of the inverter. There
are sensitive semiconductor devices vulnerable to high voltage in the inverter.
• Do not connect the output terminals T1(U), T2(V), T3(W) to AC line power.
• The CMOS IC on the primary PCB of the inverter is vulnerable to static discharge. Do not
touch the primary PCB of the inverter. If removal is required, follow recommended guidelines
for static discharge control.
CAUTION
1. Before starting, read carefully instructions.
2. Verify all connections are according to drawings.
3. Verify motor supply is connected correctly, wrong connection will destroy the inverter.
4. Check device cover is properly installed.
5. High voltages are present in this device. Switch power off and after 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 main supply.
8. Do not touch the components on the circuit boards. Static voltage discharge may destroy the
IC-circuits.
9. Check all ventilation holes are clear and uncovered.
10. Check that hot air coming from brake resistors does not cause any damage to surroundings.
11. Do not make any inspections unless the supply has been disconnected by main switch.
12. It is forbidden to use portable phones near this device with the doors open.
13. All the doors and covers must be closed when crane is in operation.
A-1

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
Examination before installation and purchase history
Every Drivecon inverter has been fully tested and examined before shipment. Please carry out
the following examination procedure after unpacking your inverter.
• Verify that the inverter model number is the same as the one you ordered.
• Check to see if there is any damage that may have occured during transit. Do not connect
the inverter to the power supply if there is any sign of damage. Report to regional sales
representative or Drivecon if you find any abnormal conditions as mentioned above.
Caution!
Failure to inspect the inverter may lead to damage of the system and possible down time. Should
you find any reason to suspect the unit itself or any part of the system to be faulty please contact
Drivecon toll free at 800-374-8266 or 847-855-9150. Be prepared to provide model number of your
controller and any other pertinant information relative to the system.
Purchase history
Please take a moment and record the following information for future reference:
Model: _______________________
Serial number: _______________________
Date purchased: _______________________
Date installed: _______________________
Installed by: _______________________
Dealer: _______________________
WARRANTY
Seller warrants that all products manufactured by it to be free from defects in material and/or
workmanship under proper and normal use by the initial user for 24 months following the date of
shipment. Seller is the sole determinant of all claims under warranty, is not responsible, and will
not issue credit for defects and damage that arise from improper installation, neglect, improper
use, unauthorized repairs or alterations, or from normal wear and tear.
During the warranty period, Seller will repair or replace, FOB its plant, any parts reported and
found to be defective by its inspection. Seller will not assume any expenses or liability for any
work done on its equipment outside its plant without its written consent, and such unauthorized
work will automatically void Seller’s warranty.
Field labor and any related expenses are not covered under this warranty. A purchase order is
required for any and all field work.
This warranty is in lieu of all other warranties expressed or implied, including warranty of mer-
chantability of fitness for a particular use.
A-2

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
Safety Precautions Precautions of operation Before turning ON power
CAUTION!
• Choose appropriate power source with correct voltage setting as the input
voltage specification of the inverter. Check line voltage phase to phase and
phase to ground for compliance.
WARNING!
• The input power source must be connected to main input power terminals L1, L2,
and L3.
• Special care must be taken while wiring the power circuit. The (L1, L2 and L3)
terminal must be connected to input power source and must not be connected to
T1, T2, or T3 output terminals by mistake. This will damage the inverter when the
power is turned on.
CAUTION!
• Do not attempt to transport the inverter by the front cover. Securely hold the inverter
by the chassis to prevent the inverter from falling.
• Install the inverter onto firm metal base or other nonflammable material. Do not
install the inverter near any flammable material to avoid fire.
• Additional ventilation fan should be installed if several inverters are installed into
one control panel to lower the temperature inside to below 50°C to avoid
overheating.
• Turn off the power supply before removal or installation of the operating panel.
Carry out installation procedure according to instructions given to avoid poor-
contact resulting in operating panel malfunction or display malfunction.
• The inverter can be easily operated over a wide speed range. Please confirm the
operating range of motor and machinery with respective manufacturers.
• Do not examine the signals on the PCB of the inverter while it is operating.
• All inverters have been adjusted properly at the factory. If adjustment is required
consult the manual and do not exceed normal operating values.
• Do not disassemble or examine the inverter before ensuring that the power is off
and the charge indicator has been extinguished.
• Insure that all safety devices on the machine are operating correctly such as: limit
switches, brakes, etc.
A-3

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
When power is turned ON
WARNING!
• Do not attempt to install or remove the control panel connector to or from the
inverter when the power supply is turned on. Otherwise, the control panel may be
damaged due to surge peak caused by the insertion or removal.
Under Operation
WARNING!
• Do not switch the motor ON with a contactor connected to the inverter's output
while the inverter is operating, otherwise the inverter may be damaged.
• Do not remove the front cover of the inverter while the power is ON to avoid
personal injury caused by electrical shock.
• When the automatic restart function is enabled, the motor machinery will be
restarted automatically. Keep a safe distance to avoid personal injury. It is not
advisable to enable this function on any manually operated system.
• Do not use an input contactor to cycle inverter ON and OFF. Repeated cycling may
cause inverter damage.
CAUTION!
• Do not touch the heatsink base.
• The inverter can be easily operated from a low-speed to high-speed range. Please
confirm the operating range of the motor and the machinery you are controlling with
their respective manufacturers.
• Do not examine the signals of the PCB of the inverter when it is under operation.
• All inverters are properly adjusted and set by the factory prior to delivery. However,
every system may require minor adjustments to be complete at time of installation.
Do not exceed the specified limits of the equipment or inverter.
• Do not proceed with disassembly or examination procedure before ensuring that the
power is off and the Power LED extinguished.
• Dangerous voltages are stored within the inverter for up to 2 minutes after removal
of line power.
• Use caution when operating from the direct keypad mode as safety travel limits will
not function.
• Do not suspend or handle loads directly over people. Refer to ANSI B30.16 as to
safe crane operating procedures.
A-4

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
During examination and maintenance
CAUTION!
• Inverter environment should be within the following specifications: 0°C - 50°C for
inverters located inside cabinet. -10°C - 40°C for inverters located outside cabinet.
Humidity should be under 95% RH non-condensing. Also, the surrounding
environment should be free from moisture or metal dust.
Typically the inverter requires no special maintenance. However we suggest
inspection of the inverter paying special attention to loose wiring connections.
Excessive accumulation of dust or dirt will also shorten the expected life of the
inverter. Periodic cleaning of the inverter with dry compressed air may be required.
WARNING!
• Insure power supply is switched OFF and the LED charge indicator has
extinguished prior to inspection or maintenance of inverter. Lock out all
equipment under repair or inspection.
A-5

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
Operating Environment Considerations
• Avoid direct sunlight
• Keep away from corrosive gas or liquid
• Keep away from oil, grease, and petroleum products
• Avoid exposure to rain or dripping water
• Avoid metal dust and dusty environments
• Avoid areas of high vibration
• Avoid extreme heat
• Keep away from high electro-magnetic interference or ultra-high frequency
energy sources. (such as arc welders or other similar machinery)
• Keep away from radioactive materials or environments
• Keep away from flammable material
• Keep surrounding area between -10 ~ +40°C.
Installation sit conditions will directly influence the service life of the
inverter. Please provide a suitable location.
Indoor mounting: 0°C - 50°C Humidity should be under 95% RH non-condensing.
Outdoor mounting: -10°C - 40°C for inverters located outside cabinet. Humidity should be
under 95% RH non-condensing.
A-6

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
Understanding and selecting the correct part number
In order to specify the correct part number to suit your needs please refer to the type code
shown below.
XT d 4 009 0 xx V
A-7

Owner's Manual
Drivecon Toll Free Ph: 1-800-374-8266
Drivecon reserves the right to alter or amend the above information without notice
Chapter B - TECHNICAL DATA
Introduction
Figure 2-1 represents the block diagram of the inverter. The inverter mechanically
consists of two units, the Power Unit and the Control Unit.
The three-phase AC line inductor (1) at the mains together with the DC bus capacitor (2)
form an LC-filter, which, together with the diode bridge (4) produce the DC-voltage supply
to the IGBT Inverter Bridge (3) block. The AC line inductor also functions as a filter
against High Frequency disturbances from the mains as well as against those caused by
the IGBT inverter to the mains. It improves the form factor of the DC bus input to the
IGBT inverter section. The entire power drawn by the inverter from the mains is active
power. The IGBT Inverter Bridge produces a symmetrical, 3-phase PWM AC-voltage to
the motor.
The Motor and Application Control Block is microprocessor based. The microprocessor
controls the motor based on the information it receives from internal sensors, parameter
settings, control I/O and control keypad. The motor and application control block controls
the motor control ASIC which, in turn, calculates the IGBT switching patterns. Gate driver
circuitry amplifies these signals for driving the IGBT inverter bridge.
Figure B-1
B-1