Drivecon XT Series User manual

 This manual is for inverter rev 5.0 with software Ind1V022.
XT Series - D2L
Service Manual
for D2L Hoisting Inverter
820 Lakeside Drive
Gurnee, IL 60031-9165
Tel: [phone]
Fax: [phone]
www.drivecon.com

Service Manual
rev 5.0 with software Ind1V022
EN DOCPPA30100-0 - 111111 PS05501 Rev:8.10.2004
 Read the instructions supplied with the hoist before installation and commissioning.
 Keep the instructions in a safe place for future reference.
Table of content
1GENERAL....................................................... 4 3.4 Brake controllers ..................................... 24
3.4.1 REC12 ...........................................................24
1.1 Technical data ........................................... 4
3.4.2 ESD141........................................................24
1.2 Type mark coding...................................... 5
4PARAMETER ADJUSTMENTS ................... 26
1.3 Basic description ....................................... 5
4.1 The display panel.................................... 26
1.4 Main components ...................................... 6
4.1.1 Navigation on the control keypad ..........27
1.5 Functional description ............................... 6
4.1.2 Value line editing............................................27
1.6 Control methods ........................................ 7
4.2 Storing and restoring parameters............. 28
1.6.1 Description of the control methods..........8
4.2.1 User parameters ............................................28
1.7 Mechanical brake control.......................... 8 4.2.2 Default parameters ........................................28
1.8 EMC ........................................................... 9 4.2.3 Keypad settings .............................................28
2INSTALLATION ............................................ 11 4.2.4 Factory settings..............................................28
2.1 Cubicles .................................................... 11 5PARAMETER DESCRIPTIONS ................... 29
2.2 Braking resistor......................................... 11 6FACTORY DEFAULT PARAMETERS......... 35
2.3 Power cabling .......................................... 11 6.1 Factory default parameters for 100Hz
motors................................................................ 35
2.3.1 Shielded motor cable................................11
2.3.2 Double collectors .......................................11 6.2 Factory default parameters for 120Hz
motors................................................................ 37
2.3.3 Cable selection...........................................11
2.3.4 Cable protection.........................................12 7SPEED SUPERVISION SETTINGS ............. 39
2.3.5 Cable length................................................13 7.1 Standard settings.................................... 40
7.1.1 Settings for sensor bearing............................40
2.3.6 Du/dt filters ..................................................13
7.1.2 Settings for pulse wheel speed sensor or
encoder (24 ppr) .........................................................40
2.4 Signal cabling ........................................... 13
2.4.1 Shielded signal cable................................13
7.2 Functional test run for SSU .................... 41
2.4.2 Reference signals......................................13 7.3 Settings for non-standard cases .............. 41
2.4.3 Sensor bearing...........................................13 8START-UP PROCEDURE............................ 43
2.4.4 Encoder........................................................14 8.1 Visual checks .......................................... 43
2.5 EMC compatible grounding .................... 14 8.2 Checks before the first test run .............. 43
2.5.1 Construction connections ........................14 8.3 Test run without load .............................. 44
2.5.2 Cable connections.....................................14 8.3.1 Functional test run for SSU .....................44
2.5.3 Shielded control cables............................14 8.4 Test run with load.................................... 44
3COMPONENTS............................................. 15 8.5 Test run with overload ............................ 44
3.1 Inverter ..................................................... 15 8.6 After the test run ..................................... 44
3.1.1 Power supply unit (PSU)..........................16 9TROUBLESHOOTING ................................. 46
3.1.2 Control unit (CSU) .....................................17 9.1 Field repair actions ................................. 46
3.1.3 Basic I/O board (Slot A) ...........................18 9.2 Typical functional problems.................... 46
3.1.4 Relay / Thermistor board (Slot B) ..........18 9.3 Inverter fault codes ................................. 47
3.1.5 SSU Speed Supervision board (Slot C)18 9.3.1 Fault time data record...............................50
3.1.6 I/O Extension board (Slot D)...................19 9.3.2 Fault Counter..............................................50
3.2 Control voltage transformer .................... 19 9.4 Inverter Alarm codes............................... 52
3.3 Speed sensors......................................... 19 10 INVERTER TROUBLESHOOTING TABLE . 53
3.3.1 Sensor bearing...........................................19 11 SERVICE ...................................................... 54
3.3.2 Encoder........................................................21 12 SPARE PARTS LIST FOR HOISTING
INVERTER ........................................................ 55
3.3.3 Proximity switch .........................................22
3.3.4 Buffer amplifier KAE234...........................23 13 DRAWINGS.................................................. 57
2/58
Drivecon Inc. reserves the right to alter or amend the above information without notice.

Service Manual
rev 5.0 with software Ind1V022
 This manual is for inverter rev 5.0 with software Ind1V022.
 CAUTION
- Before starting, read the instructions carefully.
- Verify all of the connections are in accordance to the drawings.
- Verify the motor supply is connected correctly, faulty connection will destroy the inverter.
- Check the device cover is properly installed.
- High voltages are present in this device. Switch the power off and after the display turns off, wait 5 minutes
before opening the cover.
- Insulation resistance test with a megger requires special precautions.
- Do not make any measurements inside the device when it is connected to the main supply.
- Do not touch the components on the circuit boards. Static voltage discharge may cause damage or destroy the
IC-circuits.
- Check all ventilation holes are clear and uncovered.
- Check that hot air coming from the brake resistors does not cause any danger.
- Do not make any inspections unless the supply has been disconnected by the main switch.
- It is forbidden to use radiophones or portable phones near this device with the doors open.
- All the doors and covers must be closed during crane operation.
- Inverter is 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.
3/58
Drivecon Inc. reserves the right to alter or amend the above information without notice.

Service Manual
rev 5.0 with software Ind1V022
1 GENERAL
1.1 Technical data
Power class 002F 003F 004F 005F 007F 011F 015F 018F 022F 030F 037F 045F 055F
Power (kVA) at 400V 4.5 5.5 7 9 13 17
22 29 33 40 50 60 75
Output current In (A) 6.5 8 10 13 18 24 32 42 48 60 75 90 110
Max. current 1min (A) 10 12 15 20 27 36 48 63 72 90 113 135 165
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
Encoder feedback EA+/- and EB+/-; 0/24V; 3kΩ; floating differential inputs
Control features
Control method Open loop vector control
Frequency control range 0 ... 250Hz
Frequency command Motor potentiometer or 2-4-step controller
Limit switch functions Slowdown and stop limit inputs for both directions
Speed control range sN... 100% (sN= motor nominal slip)
Speed accuracy 1% of nominal speed at speed range 10 ... 100%
1/3 of motor nominal slip at speed below 10%
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
Ground fault Provided by electronic circuitry
Overspeed / stall,
Speed difference supervision Independent measurement using sensor bearing, 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
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.
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Service Manual
rev 5.0 with software Ind1V022
1.2 Type mark coding
D2L can be summarized as a "crane hoisting motor control system, 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.
XT d 4 009 0 xx v x
XT Family Type
d d=scalar drive, e=vector drive, s=scalar panel, v=vector panel
r=regen base drive, I=inverter base drive, w= water cooled
4 Supply voltage
4=380 - 500VAC, 50/60Hz
009 Rated Amps
009 = 9 A
0 Option PCB’s
0,1,2,3,4,5,6,7,8,9
xx Software revision
V Special options
V= Varnished
x Not used
1.3 Basic description
D2L has many advantages and offers many new features, when compared to other inverter based systems,
which might be used in crane applications.
Inverter The inverter in D2L 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 D2L has exactly the same interface with pre-designed locations for 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 D2L include the brake contactor for disk brakes. D2L also includes it’s own DC-rectifier.
Electrical
Braking
D2L includes the braking transistor, which is dimensioned for every crane application. For resistor braking D2L
includes a braking resistor.
Control methods D2L can be controlled by the electronic potentiometer control with 2-step or 3-step pushbuttons and by the
multistep control with 2-4-step controllers. Both these control methods are available with every D2L.
Limit switch functions D2L has built-in slowdown (S11, S21) and stop limit switch (S12, S22) functions for both running directions.
Speed supervision D2L includes 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.
Protections D2L includes a motor thermal protection, which is based on motor temperature measurement by thermistors
placed in motor windings. A great number of other protections included in every D2L are shown in the technical
data.
Tested parameters D2L includes tested parameters with different motors for all power ratings. This is a benefit, which makes every
D2L delivery a proven solution The tested and pre
-
set motor parameters enable a q
uick start
-
up
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Service Manual
rev 5.0 with software Ind1V022
D2L delivery a proven solution. The tested and pre-set motor parameters enable a quick start-up.
1.4 Main components
The main components are:
D2L
A1 Inverter
F7 Brake supply circuit breaker 007 - 055
K7 Brake contactor
G1 Brake control unit REC12 002-011
G1 Brake control unit ESD141 015-055
F71 Circuit breaker for the second brake contactor 055
K71 Second brake contactor 055
The most important external components are:
R1 Braking resistor unit
M1 Hoisting motor
Y1 Mechanical brake
A5 KAE234 Proximity switch buffer amplifier for speed sensor
B5 Speed sensor
B6 Thermal sensor for motor protection
Overload protection device
Control devices (switches, pushbuttons etc.)
Limit switches
Example: Layout of D2L030
Z1
K7F7
G1
X1
A
1
CM1
Z2 Z3
1.5 Functional description
Operation when power is switched on
- Stop limit switches S12 & S22 and slow down limit switches S11 & S21 are assumed to be closed, as well as
the emergency stop button ES.
- The control voltage is supplied to X1:37. The main voltage is connected to inverter power supply and inverter
wakes up. 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.
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Service Manual
rev 5.0 with software Ind1V022
- If either of the direction signals S1 or S2 is on, the D2L display shows F6 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 chapter "Control methods".
- Hoisting (lowering) starts when switch S1 (S2) closes. Closing the contact ROB2 on A1 energizes K7, which
opens the brake (in model 055 the brake can be controlled also by K71). D2L accelerates according to the
acceleration ramp setting to the selected speed.
- When the switch S1 (S2) opens D2L stops according to the deceleration ramp setting and the brake closes.
- R1 dissipates the regenerated energy during 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 contact RDY, stops the operation of inverter.
- In case of overload, motor overheating etc. the hoisting can be disabled by cutting the direction signal in
terminal X1:8.
- Thermistor relay function, which can be used when needed.
- When the stop limit switch S12 or S22 opens, K7 (K71 in model 055F) 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 sensor 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 A5 amplifies the sensor pulses and filters out disturbances. The amplifier
is located close to the sensor.
1.6 Control methods
There are three different control methods (command modes) available:
1 EP2 Electronic motor potentiometer function.
Stepless control using a 2-step controller.
2 EP3 Electronic motor potentiometer function.
Stepless control using a 3-step controller.
3 MS Multistep control (4 steps)
The control mode of inverter is selected by parameter P2.1.4. See chapter Control methods. The parameters
assigns digital inputs S1, S2, OK, DIA3-DIA5 and DID1-DID5.It is not possible to chance the functions of the
inputs separately. The state of inputs can be checked from parameters V4.7.12 and V4.7.13. The input
assignment according to the selected mode is explained in the following table.
Control mode EP EP3 MS
Parameter P2.1.4 1 2 3
Signal Terminal
S1 X1:8 S1 S1 S1
S2 X1:9 S2 S2 S2
OK X1:7 OK OK OK
DIA3 X1:10 AP AP MS2
DIA4 X1:11 Not used HOLD MS3
DIA5 X1:12 Not used not used MS4
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Service Manual
rev 5.0 with software Ind1V022
DID1 X1:38 FWE FWE FWE
DID2 X1:39 S11 S11 S11
DID3 X1:40 S21 S21 S21
DID4 X1:41 S12 S12 S12
DID5 X1:42 S22 S22 S22
Desired speed levels for multi-step control mode are selected with following parameters
Speed Parameter Input
Speed 1 P2.2.8. / P2.2.9. S1/ S2
Speed 2 P2.1.7. MS 2
Speed 3 P2.1.8. MS 3
Speed 4 P2.1.9. MS 4
1.6.1 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
fwd
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
fwd
rev
time
EP3-mode
MS-control requires a 2 to 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
fwd
rev
time
speed
controller
position
MS-mode
1.7 Mechanical brake control
D2L has a brake contactor to control electromechanical disk brake of hoisting motor. 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.
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.
8/58
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Service Manual
rev 5.0 with software Ind1V022
During a direction change, the brake is kept open all the time. D2L decelerates 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.
Models 002F-011F have a built-in REC12 brake control unit, which is a line voltage half-wave rectifier. The
half-wave type rectifier reduces losses and is enough to open the brake. There is a contactor to switch the line
voltage on and off.
Models 015F-055F have a built-in ESD141 brake control unit, which is a line voltage full/half-wave rectifier.
Full-wave rectification is used to open the brake quickly. Then, the rectifier changes to a half-wave type, which
reduces losses, but is enough to keep the brake open. There is a contactor to switch the line voltage on and
off. The same contactor also disconnects the DC-voltage directly from the brake coil, which guarantees that
the brake closes fast.
Model 055F includes a 3-phase AC-supply for the brake control. D2L controls this line and it is protected by an
adjustable circuit breaker (max. 4.0A). When a shoe brake is used, brake closing is speeded up by capacitors.
They are connected in parallel with the brake via the brake contactor NC-contacts. The connection is partially
ready in D2L. Only the capacitors must be added outside D2L. This connection can also be used to control 2-
phase disk brakes or a separate KA372B brake control unit.
1.8 EMC
The shortening "EMC" stands for the Electro Magnetic Compatibility. According to the EMC directive "the
apparatus shall be so constructed that:
• The electromagnetic disturbance it generates does not exceed a level allowing other apparatus to
operate as intended
• The apparatus has an adequate level of intrinsic immunity of electromagnetic disturbance to enable it
to operate as intended."
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.
First environment means environment that
includes domestic premises and also
establishments directly connected to a low-
voltage power supply network.
PDS
Second environment means environment that
includes all establishments other than those
directly connected a low-voltage power supply
network
PDS
Fulfilled EMC-standards • Inverter fulfils the immunity requirements defined in the EN
61800-3 Amendment 11 (2000) for the second environment.
• Inverter fulfils the emission re
q
uirements of the EN 61800-3 A11
9/58
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Service Manual
rev 5.0 with software Ind1V022
2000 for the second environment.
10/58
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Service Manual
rev 5.0 with software Ind1V022
2 INSTALLATION
2.1 Cubicles
Inverter is delivered with external braking resistors.
See drawings of resistors for sizing.
2.2 Braking resistor
See design drawings
2.3 Power cabling
2.3.1 Shielded motor cable
In crane application inverter fulfils EN61800-3/A11 (IEC 1800-3) second environment radiated emission
requirements without shielded motor cable.
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 fulfil the first environment emission
requirements.
2.3.2 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.
2.3.3 Cable selection
Cabling for inverter 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 ED ≤60% and ambient temperature +40°C (104°F). A higher ambient
temperature may require increased cable sizes. The input current does not exceed the continuous current
(Icont) of inverter, so it is selected to be the dimensioning current. If the actual load current is below inverter
continuous current, then the fuses and the supply cable may be dimensioned according to the load current.
Power class 002 003 004 005 007 011 015 018 022
Continuous current ICONT A 6.5 8 10 13 18 24 32 42 48
Fuse A
10 10 10 16 20 25 35 50 50
Max motor cable length m 50 50 50 50 50 50 50 50 50
Ft
160 160 160 160 160 160 160 160 160
Motor cable 40oC mm21.5 2.5 2.5 2.5 4 6 10 10 10
104oF AWG
14 14 14 12 10 10 8 8 6
Braking resistor cable 40oC mm22.5 2.5 2.5 2.5 2.5 2.5 2.5 4 4
104oF AWG
14 14 14 14 14 14 14 12 12
Power class 030 037 045 055
11/58
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Service Manual
rev 5.0 with software Ind1V022
Continuous current ICONT A 60 75 90 110
Fuse A
63 80 100 125
Max motor cable length m 50 50 75 75
Ft
160 160 240 240
Motor cable 40oC mm216 25 35 35
104oF AWG
6 4 2 2
Braking resistor cable 40oC mm210 10 16 16
104oF AWG
8 8 6 6
2.3.4 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 inverter protects both the supply and the motor cables. The fuses of the supply
provide the short circuit protection.
12/58
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Service Manual
rev 5.0 with software Ind1V022
2.3.5 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
Up
Il
AF
×
×
×
×= 5.1 43.2
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
2.3.6 Du/dt filters
If D2L is not mounted on the crane, there has to be du/dt filter at motor supply. Also if total motor cable
length ( sum of motor cables ) is over 100m with D2L002 – D2L005 or over 200m with D2L007 – D2L055,
there has to be du/dt filter at motor supply.
D2L Platthaus du/dt filter Length (mm) Width (mm) Height (mm) Weight (kg) ID
002 – 003 ULC-910-920 100 110 180 1.2 52306553
004 – 005 ULC-914-931 125 110 200 3 52306554
007 – 018 ULC-918-951 155 125 225 7 52306555
022 – 045 ULC-923-927 190 135 260 12 52306556
055 ULC-942-1044 240 175 310 22 52306557
 Du/dt filter should be as near D2L as possible
 Note! All control cables must be placed as far from the motor and braking resistor cables as
possible.
2.4 Signal cabling
2.4.1 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 to 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.
2.4.2 Reference signals
Shielded round cables must be used for analog reference signals. The shield is to be grounded only at one
end of the cable.
2.4.3 Sensor bearing
The cable for the sensor bearings must be shielded round cable and grounded 360° at both ends.
13/58
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Service Manual
rev 5.0 with software Ind1V022
2.4.4 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 360° 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° grounding should be used to minimize disturbances.
 If control cable length is over 100m (from transformer to inverter) or inverter is not mounted on
the crane, make sure that Basic I/O board (Slot A) is at least revision 271G and I/O Extension
board (Slot D) is at least revision 266H
2.5 EMC compatible grounding
2.5.1 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.
2.5.2 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.
2.5.3 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 be as integrity as possible. Spare conductors should be grounded in the both ends. All shielded cable
shields should be 360° grounded.
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Service Manual
rev 5.0 with software Ind1V022
3 COMPONENTS
3.1 Inverter
Inverter (D2V) includes Power supply unit (PSU) and Control unit (CSU), which are separate parts. PSU
includes supply, brake resistor and motor connections. IGBTs are placed to PSU. Microprocessors and ASIC
are placed to CSU. Same CSU can be used in every power class.
D2V In
1min
Imax
Weight
kg
Weight
lbs
D2V002NF1e000 6,5 10 6 13
D2V003NF1e000 8 12 6 13
D2V004NF1e000 10 15 6 13
D2V005NF1e000 13 20 6 13
D2V007NF1e000 18 27 10 22
D2V011NF1e000 24 36 10 22
D2V015NF1e000 32 48 20 44
D2V018NF1e000 42 63 20 44
D2V022NF1e000 48 72 20 44
D2V030NF1e000 60 90 37 82
D2V037NF1e000 75 113 37 82
D2V045NF1e000 90 135 37 82
D2V055NF1e000 110 165 61 135
e defines emission level ( 0 = EMC level 0, N = EMC level N/S )
The main circuit diagram of D2V002 – D2V005
L1
L2
L3
DC-
DC+
BR B+ B-
U/T1
V/ T2
W/T3
WH_G
WH_D
WL_G
WL_D
VH _G
VH _D
VL_D
UL_G
UL_D
BRK_G
BRK_D
UH_D
UH_G
VL_G
The main circuit diagram of D2V007 – D2V055
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Service Manual
rev 5.0 with software Ind1V022
DC-
DC+
BR B+ B-
WH_G
WH_D
WL_D
VH _G
VH _D
VL_G
VL_D
BRK_G
BRK_D
U/T1
V/ T2
W/T3
L1
L2
L3
UH_D
UH_G
UL_G
UL_D
WL_ G
3.1.1 Power supply unit (PSU)
Power supply unit (PSU) includes the main circuit components. PSU has connectors for supply cables, motor
cables and braking resistor cables. PSU also includes a D-connector for CSU-connection.
Main supply voltage terminals
L1 Mains L1
L2 Mains L2
L3 Mains L3
PE Protective earth
DC-bus terminals
B- DC-bus negative
B+ DC-bus positive / Brake resistor positive
R- Brake resistor negative
Motor output voltage terminals
U/T1 Motor U
V/T2 Motor V
W/T3 Motor W
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Service Manual
rev 5.0 with software Ind1V022
3.1.2 Control unit (CSU)
Control unit (CSU) includes a control board with five board slots for option boards and a control keypad for
parameter adjustments. CSU is connected to PSU through a D-connector.
Yellow Red Status
blinking
0.5Hz
blinking
0.5Hz
Everything is OK.
IEC Application Scheduler is running
and Application is running
blinking
0.25Hz
blinking
0.5Hz
IEC Application Scheduler is running
and Application is NOT running
OFF blinking
0.5Hz
IEC Application Scheduler and
Application are NOT running
Green Status
ON PSU ready
OFF PSU not ready
YELLOW
RED
GREEN KEYPAD
A
BCDE
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Service Manual
rev 5.0 with software Ind1V022
3.1.3 Basic I/O board (Slot A)
Basic I/O-Board is in CSU slot A. It has two board levels, one for electronics level signals (terminals 1-10) and
one for control voltage signals (42-240Vac).
NXOPTA6 / Basic I/O board ID: 52288046
Terminal Signal name Description
1 PUR Not used
2 +15 V Not used
3 AIN1+ Analog input 1 (0-10V)
4 AIN2+ Not used
5 AIN- Common for analog input and output signals
6 AOUT1 Not used
7 AOUT2 Analog output 2 (0-10V)
8 DOA1 Not used
9 0V I/O ground terminal
10 +24V Not used
11 S1 Digital input 42-240Vac 50/60Hz (Direction S1)
12 S2 Digital input 42-240Vac 50/60Hz (Direction S2)
13 DIA3 Digital input 42-240Vac 50/60Hz
14 DIA4 Digital input 42-240Vac 50/60Hz
15 DIA5 Digital input 42-240Vac 50/60Hz
16 OK Digital input 42-240Vac 50/60Hz (OK-signal).
OK-input is connected straight to the ASIC.
Inverter is ready to operate when OK-signal is
active “1”.
17 COM Common for 42-240Vac 50/60Hz
18 COM Common for 42-240Vac 50/60Hz
1234567 8 9 10
11 12 13 14 15 16 17 18
The threshold voltage for digital inputs S1, S2, DIA3, DIA4, DIA5 and OK is 35VAC.
3.1.4 Relay / Thermistor board (Slot B)
NXOPTA3 / Relay / Thermistor board ID: 52305690
Terminal Signal name Description
21 ROB1
22 ROB1
23 ROB1
Relay output, 250V 8A
25 ROB2
26 ROB2
Relay output, 250V 8A, normal open
28 T1
29 T2
Thermistor input, double isolated,
Rtrip=4.7kΩ
25 2621 22 23 28 29
3.1.5 SSU Speed Supervision board (Slot C)
SSU is in CSU slot C, see chapter Speed supervision settings.
SSU / Speed supervision unit ID: 52288044
Terminal Signal name Description
1 EA+ Threshold voltage 10VDC
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Service Manual
rev 5.0 with software Ind1V022
2 EA- Threshold voltage 10VDC
3 EB+ Threshold voltage 10VDC
4 EB- Threshold voltage 10VDC
5 +24V +24VDC short circuit protected
6 0V Common for encoder supply
28 ROC1
29 ROC1
Relay output, 250V 8A, normal open
Relay contact ROC1 closes when inverter is powered and no faults occurs
Relay contact ROC1 opens if the SSU has tripped in:
Overspeed
Speed difference
Zero speed
Relay test fault
Watch dog fault
LED Blinking Status
Red 1Hz OK
Yellow 0.25Hz OK
Yellow 4Hz Board internal fault or communication fault with control unit
1 2 3 4
ON OFF
S1
S2
S3
123456
S1
S2
S3 RED
YELLOW
28 29
3.1.6 I/O Extension board (Slot D)
NXOPTB9 / I/O Extension board ID: 52305691
Terminal Signal name Description
1 DID1 Not used
2 DID2 42-240Vac 50/60Hz
3 DID3 42-240Vac 50/60Hz
4 DID4 42-240Vac 50/60Hz
5 DID5 42-240Vac 50/60Hz
6 COM Common for DID1-DID5
7 ROD1
8 ROD1
Relay output, 250V 8A, normal open
For fan of braking resistor unit
The threshold voltage for digital inputs DID1-DID5 is 35VAC.
LED Blinking Status
Yellow 0.25Hz OK
Yellow 4Hz Board internal fault or communication fault with control unit
YELLOW
123 4 567 8
3.2 Control voltage transformer
Power of control voltage transformer has to be n * 50VA + 50VA (min. 250VA), n = number of inverters.
This power does not have to be added to otherwise needed transformer power.
3.3 Speed sensors
3.3.1 Sensor bearing
D2L needs information about the motor rotation speed for stall, speed difference and overspeed supervision.
Order codes of the bearing sensors are shown in the table below.
Motor type Motor code Pulses per revolution Order code Supply voltage Max load
MF10MA200 T1 32 NM768NR3 24V DC 20 mA
MF10MB200 T2 32 NM768NR3 24V DC 20 mA
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Service Manual
rev 5.0 with software Ind1V022
MF10MC200 T3 32 NM768NR3 24V DC 20 mA
MF11MA200 T4 64 NM768NR4 24V DC 20 mA
MF11MB200 T5 64 NM768NR4 24V DC 20 mA
MF13Z-200 T6 80 NM768NR5 24V DC 20 mA
MF13ZA200 T7 80 NM768NR5 24V DC 20 mA
MF13ZB200 T8 80 NM768NR5 24V DC 20 mA
MF13ZC200 T9 80 NM768NR5 24V DC 20 mA
MF13X-200 TA 80 NM768NR5 24V DC 20 mA
Sensor bearing requires KAE234 buffer amplifier. If channel A+ is damaged, channel B+ can be used instead
in emergency situations.
Signal name Sensor bearing
wire colour
Wire colour between KAE234 and
motor plug
Terminal number
+24V Red Brown KAE234:6
0V Black Green KAE234:2
A+ White White KAE234:1
B+ Blue not connected not connected
3
4
7
6
1
2
OUT
+24V
0V
:55
:51
:56
X1
+24V
EA+
0V
INVERTER
WHITE
BLACK
+24V
A
0V
RED
:52
EA-
BROWN
GREEN
WHITE
 Critical damage if: The supply voltage is over 28V or a short circuit between the signal and
the supply, or induction heating or hammer mounting. In case of sensor damage, the whole
motor has to be changed.
Buffer amplifier must be located as close to the sensor bearing as possible (maximum distance 2.5m)
The cable between the buffer amplifier and D2L must be
- as far as possible from the cables of motor and braking resistor (minimum distance >20cm)
- a shielded and twisted cable
- grounded (the shield) at both ends, 360°grounding on D2L terminal
- the shield should be grounded always when going through terminals
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