Drivecon XT Series Service Manual
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Drivecon XT Series Service Manual

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Service Manual
Rev 5.6B5 with software Pro2V080
and Pro2V081
XT SERIES
Service Manual
820 Lakeside Drive – Gurnee, IL 60031
Phone: 1-800- 374-8266
Fax: (847) 855-9650
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 © 2006 Drivecon, Inc. All rights reserved.

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  • Page 1 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 © 2006 Drivecon, Inc. All rights reserved.
  • Page 2 13. All the doors and covers must be closed during crane operation. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 3: Table Of Contents

    Service on hoist motor/encoder/brake with Brake Slip feature active………...40 PARAMETER DESCRIPTIONS ..................41 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 4 Re-forming after a long storage period ............75 DRAWINGS ........................76 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 5: General

    Maxim um accel erati on ampl itude 1G ( 9.81m/s²) at 15.8- 150Hz Conf orms to LV and EMC directives (optional). Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 6: Type Mark Coding

    5. NXP2 and lacquered boards 6. NXP2 and fiber optic link and lacquered boards Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 7: Basic Description

    All other protection functions are listed in the technical data. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 8: Functional Description

    This amplifier should be located as close to the motor as possible. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 9: Control Methods

    PLC. Parameter selection and proper tuning activ ate the synchronization functionality. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 10 / rev MS-mode Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 11: Mechanical Brake Control

    This is how 1000:1 speed control is achieved. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 12: Emc

    Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 13: Fulfilled Emc-Standards

    EMC Plan can be used as the guide to solve those. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 14: Installation

    Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 15 **For wire sizing information for higher duty cycles and/or drives larger than listed above, please contact Drivecon. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 16: Control Wiring

    Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 17: Emc Compatible Grounding

    Spare conductors should be grounded in both ends to avoid antenna behavior. All shielded cable shields should be 360° grounded. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 18: Start-Up Procedure

    - Make sure that the external connections and programming of the digital and analog inputs are done according to the application requirements. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 19: Test Run Without Load

    - Sav e user parameters in Control Unit at parameter 4.1.2. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 20: Parameter Adjustments

    Warning! Running via keypad can cause a hazardous situation. Keypad control must not be used. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 21: Navigation On The Control Keypad

    Warning! Changing parameter settings during running may cause a hazardous situation. Parameter settings must not be changed during operation. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 22: Passwords

    Resets whole H8 Fault History when display in sublevel of H8 menu. enter Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 23: Monitoring

    Sway Ctrl Height V4.6.30 Calibration Pos V4.6.31 Profibus Status V4.6.32 Bus Cycle Time Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 24: Input Selections

    S11 & S21 P3.2.1.20 P3.2.1.21 P3.2.1.22 MF1 Input P3.2.1.24 MF2 Input Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 25: Speed Supervision Settings

    See section 4.6 of this manual for further information about this feature. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 26 If ESR is not used, set S2:4 + S3 equal to S2:1 and S1. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 27: Functional Test Run For Ssu

    The test makes the crane stop suddenly that may cause a dangerous situation. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 28: Open Loop Motor Parameter Adjustments

    Maximum Frequency S2 the nominal f requency on motor rating plate). Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 29: Open Loop Autotuning For Traveling, Frequency Control

    Rs Voltage Drop = [(2217 * Resistance * P3.4.1.4) / P3.4.1.1] Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 30: Open Loop Manual Tuning For Traveling, Frequency Control

    (V4.20). The driv e is ready to operate after these adjustments. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 31: Closed Loop Motor Parameter Adjustments

    Check the operation of limit switches before performing closed loop tuning. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 32: Closed Loop Autotuning, Speed Control

    Because of speed limitations in step 2 and step 3, tandem drives have to be tuned simultaneous. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 33 Adjusted parameters in autotuning step 3 are P3.4.3.1 Slip Adjust and P3.3.14.1 Accel Torque. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 34 In case of traveling motion, contact factory for more information. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 35: Closed Loop Manual Tuning For Hoisting, Speed Control

    480 V 500 V V4.18 Lower Limit Voltage V4.18 Upper Limit Voltage Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 36 The driv e is ready to operate after these manual-tuning adjustments. If there is any v ibration, fine adjustment of speed controller parameters may improv e the operation. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 37 Record v alues of P3.4.3.3 P3.4.3.4 Speed Ctrl Kp Speed Ctrl Ti Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 38: Brake Slip Feature

    Consult above warning label. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 39: 4.6.2 Activation Of Brake Slip Feature

    - Only trained and qualified personnel experienced with inverters equipped with this feature should attempt this testing. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 40: 4.6.4 What To Do In Case Of Brake Slip

    - Familiarize yourself with this section 4.6 from the beginning prior to operating the crane . Only qualified and trained operators should operate the crane. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 41: Service On Hoist Motor/Encoder/Brake With Brake Slip Feature Active

    Power should be turned off/crane tagged and locked prior to any serv ice being performed on the crane. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 42: Parameter Descriptions

    + G3.8 System Bus G3.8.3 Synchronization G3.8.4 Tandem + G3.9 PLC Parameters Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 43 Debug S6.9 Power Monitor S6.11 Power Multimon. Active Faults Fault History Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 44 MF2 Input Same as 3.2.1.11 P3.2.1.25 MF2 Operation Same as 3.2.1.23 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 45 3 = 2-10V Unsign P3.2.4.2.5 Aout2 Filter Time 0.10 0.10 0.10 0.10 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 46 45.00 45.00 45.00 P3.3.9.5 Multistep 5 Freq 60.00 60.00 60.00 60.00 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 47 Max Filter Range P3.3.16.3 Max Filter P3.3.16.4 Min Filter 0.00 0.00 0.00 0.00 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 48 Current Ctrl Ti P3.4.1.23.3 Accel Comp TC 0.10 0.10 0.10 0.10 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 49 CL Autotune Mode 0 = Normal 1 = Tandem P3.4.3.6.5 SlipAdj1 Ctrl TC Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 50 Current Ctrl Ti P3.4.4.23.3 Accel Comp TC 0.10 0.10 0.10 0.10 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 51 CL Autotune Mode 0 = Normal 1 = Tandem P3.4.6.6.5 SlipAdj2 Ctrl TC Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 52 Process Data 7 Same as 3.5.2.1 P3.5.2.6 Process Data 8 Same as 3.5.2.1 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 53 0 = Not Used 1 = Fault P3.6.15 Ramp Stretching P3.6.16 BrakeSuperv Time Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 54 Unit PW 3 Description P3.9.1 PLC Parameter 1 P3.9.2 PLC Parameter 2 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 55: Components

    ( 0 = unlimited or IT network, N = limited or grounded Y network ) Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 56 U/T1 V/T2 W/T3 VL_G WL_G UL_G BRK_G UL_D VL_D WL_D BRK_D Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 57: Power Supply Unit (Psu)

    Application are NOT running YELLOW Green Status PSU ready PSU not ready Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 58: Basic I/O Board (Slot A)

    15 16 17 18 1 2 3 4 5 6 7 8 9 10 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 59: Relay / Thermistor Board (Slot B)

    0.25Hz Yellow Board internal fault or communication fault with control unit Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 60: I/O Extension Board (Slot D)

    Board internal fault or communication fault with control unit 25 26 25 26 28 29 Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 61: Profibus Board (Slot E)

    - Profibus cable broken, cable loose or Prof ibus master off line Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 62: Reference Potentiometer

    Control voltage and speed as a f unction of turning angle. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 63: Speed Sensors

    (< 5cm) to the motor cables and braking resistor cables. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 64: Bearing Sensor

    - the shield should be grounded always when going through terminals Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 65: Proximity Switch

    Blue Schönbuch INSOR ICDM 8802 Baumer IFRM08N1501/L Honeywell 3GT101DC Baumer IFRM08N1501/S35L Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 66: Buffer Amplifier Kae234

    The picture beside presents the pulse output. 0± 1V Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 67: Brake Controllers

    K7 contacts and the brake coil. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 68: Troubleshooting

    (requires same software versions). Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 69: Inverter Fault Codes

    Fault is not stored into fault SSU settings and SSU relay operation history. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 70 Motor is overloaded. if no overload exists, then check motor temperature model parameters Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 71 S5 = SSU-board is missing or system load is too high Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 72 Check: brake operation pulse sensor/encoder function and cabling stall supervision settings Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...
  • Page 73 Check: Input Signal and Profibus are different wiring of limit switches Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 74: Fault Time Data Record

    F48, F50, F54, F55, F60, F64, F65, F71, F72, F73, F75 V4.5.25 Total Faults Total number of all faults. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 75: Inverter Alarm Codes

    Keys are incorrect or missing Licence Key numbers Sway Control mode Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 76: Service

    Discharging will take several minutes and resistor will get hot. Measure the voltage before touching the capacitor terminals. Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

  • Page 77: Drawings

    Service Manual Page 76 Pro2V080 Pro2V081 DRAWINGS Drivecon reserves the ri ght to al ter or amend the above i nform ati on wi thout noti ce12/18/06 • rev 5.6B5 for Pro2V080 or Pro2V081 softwar e...

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