Drivecon XT Series Service Manual
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Drivecon XT Series Service Manual

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Service Manual
Rev 6.0 with software Ind2V101
Service Manual
9505 72nd Ave. Suite 100
Phone: 1-800- 374-8266
Fax: (262) 947-0526
www.drivecon.com
! ! "
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Summary of Contents for Drivecon XT Series

  • Page 1 Service Manual Rev 6.0 with software Ind2V101 Service Manual 9505 72nd Ave. Suite 100 Phone: 1-800- 374-8266 Fax: (262) 947-0526 www.drivecon.com ! ! "...

  • Page 2: Table Of Contents

    ESD141 ................................22 PARAMETER ADJUSTMENTS ............................23 The display panel ................................. 23 4.1.1 Navigation on the control keypad ......................... 24 4.1.2 Value line editing ..............................24 Drivecon Inc. reserves the right to alter or amend the above information without notice // 2/59...
  • Page 3 Inverter Alarm codes ..............................57 TROUBLESHOOTING TABLE ............................58 SERVICE ..................................59 13.1 DC-bus electrolytic capacitors............................59 13.1.1 Re-forming after a long storage period......................... 59 Drivecon Inc. reserves the right to alter or amend the above information without notice // 3/59...
  • Page 4 Drive is not intended to be used in a low-voltage public network, which supplies domestic premises. Radio frequency interference is expected if used in such a network. Drivecon Inc. reserves the right to alter or amend the above information without notice // 4/59...

  • Page 5: General

    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. Drivecon Inc. reserves the right to alter or amend the above information without notice // 5/59...

  • Page 6: Type Mark Coding

    If either of the direction signals S1 or S2 is on, the display shows F6 and driving can begin only after the direction signals have been off for a while. Drivecon Inc. reserves the right to alter or amend the above information without notice // 6/59...

  • Page 7: Description Of The Control Modes

    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 Drivecon Inc. reserves the right to alter or amend the above information without notice // 7/59...

  • Page 8: Ep2-Control

    A. Controller position B. Speed “decelerate to zero” step 1 “drive minimum speed” step 2 “drive speed2” step 3 “drive speed3” step 4 “drive maximum speed” Drivecon Inc. reserves the right to alter or amend the above information without notice // 8/59...

  • Page 9: Mechanical Brake Control

    Amendment 11 (2000) for the second environment. N level products fulfil the emission requirements of the EN 61800-3 A11 2000 for the second environment. Drivecon Inc. reserves the right to alter or amend the above information without notice // 9/59...

  • Page 10: Installation

    The overload protection of inverter protects both the supply and the motor cables. The fuses of the supply provide the short circuit protection. Drivecon Inc. reserves the right to alter or amend the above information without notice // 10/59...

  • Page 11: Cable Length

    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 Drivecon Inc. reserves the right to alter or amend the above information without notice // 11/59...

  • Page 12: Emc Compatible Grounding

    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. Drivecon Inc. reserves the right to alter or amend the above information without notice // 12/59...

  • Page 13: Components

    The main circuit diagram of XT4016 – XT4105 UH_G VH_G WH_G UH_D VH_D WH_D U/T1 V/T2 W/T3 VL_G WL_G UL_G BRK_G UL_D VL_D WL_D BRK_D Drivecon Inc. reserves the right to alter or amend the above information without notice // 13/59...

  • Page 14: Power Supply Unit (Psu)

    0.5Hz and Application is NOT running blinking IEC Application Scheduler and 0.5Hz Application are NOT running YELLOW Green Status PSU ready PSU not ready Drivecon Inc. reserves the right to alter or amend the above information without notice // 14/59...

  • Page 15: Basic I/O Board (Slot A)

    Relay output, 250V 8A ROB1 ROB2 Relay output, 250V 8A, normal open ROB2 Thermistor input, double isolated, =4.7kΩ trip 21 22 23 25 26 28 29 Drivecon Inc. reserves the right to alter or amend the above information without notice // 15/59...

  • Page 16: Ssu Speed Supervision Board (Slot C)

    ROD1 The threshold voltage for digital inputs DID1-DID5 is 35VAC. Blinking Status Yellow 0.25Hz Board internal fault or communication fault with control Yellow unit Drivecon Inc. reserves the right to alter or amend the above information without notice // 16/59...

  • Page 17: System Bus Board (Slot E, Option)

    Wire color between KAE234 and Terminal number motor plug wire color +24V Brown KAE234:6 Black Green KAE234:2 White White KAE234:1 Blue Not connected Not connected Drivecon Inc. reserves the right to alter or amend the above information without notice // 17/59...

  • Page 18: Encoder

    Encoder connection examples are shown below. All signal wires shall be included inside a single shielded cable. Power supply to the encoder may also be included in the same cable. Drivecon Inc. reserves the right to alter or amend the above information without notice // 18/59...
  • Page 19 Some problems may occur when using shielded flat cable or in situations where the encoder cable has been placed too close (< 5cm) to the motor cables and braking resistor cables. Drivecon Inc. reserves the right to alter or amend the above information without notice // 19/59...

  • Page 20: Proximity Switch

    Honeywell 3GT101DC Hall-sensor requires tooth movement past the sensor. A motionless tooth can not gernerate a pulse. Drivecon Inc. reserves the right to alter or amend the above information without notice // 20/59...

  • Page 21: Buffer Amplifier Kae248

    The released brake contactor also opens the brake coil DC-circuit, which speeds closing of the brake. The purpose of the varistor there is overvoltage protection for K7 contacts and the brake coil. Brake Drivecon Inc. reserves the right to alter or amend the above information without notice // 21/59...

  • Page 22: Esd141

    DC-circuit, which speeds closing of the brake. The purpose of the varistor there is overvoltage protection for K7 contacts and the brake coil. Drivecon Inc. reserves the right to alter or amend the above information without notice // 22/59...

  • Page 23: Parameter Adjustments

    Stops the motor if keypad is the active control place STOP WARNING! Changing parameter settings during running may cause a hazardous situation. Parameter settings must not be changed during running. Drivecon Inc. reserves the right to alter or amend the above information without notice // 23/59...

  • Page 24: Navigation On The Control Keypad

    - “Load User Par / Enter <-“, press “Enter” After restoring always check the motor parameters. Parameters in use can be compared to User parameters by parameter S 6.6.2. Drivecon Inc. reserves the right to alter or amend the above information without notice // 24/59...

  • Page 25: Default Parameters

    - “All param.” blinks on display, confirm with enter. After restoring always check the motor parameters. 4.2.4 Factory settings Factory settings are not used. Drivecon Inc. reserves the right to alter or amend the above information without notice // 25/59...

  • Page 26: Parameter Descriptions

    Start current. Current level, which is used in motor starting situation. Hoisting application: default value is motor’s nominal current, but not over nominal current of the inverter. Drivecon Inc. reserves the right to alter or amend the above information without notice // 26/59...
  • Page 27 Increases or decreases the Flux Current controller values P2.3.1&2 to 0 – 100 % direction S2. Must not be changed. Used in hoisting application. Drivecon Inc. reserves the right to alter or amend the above information without notice // 27/59...
  • Page 28 OPT-D1 option board is installed in the slot E and input DID1 is on. Next Address P2.4.2. Next system bus node address 0 - 4 Last Address P2.4.3. Last system bus node address 0 - 4 Drivecon Inc. reserves the right to alter or amend the above information without notice // 28/59...
  • Page 29 State of relay output ROB2, K7 0=OFF, 1=ON ROC1 State V4.3.3 State of relay output ROC1 0=OFF, 1=ON ROD1 State V4.3.4 State of relay output ROD1 0=OFF, 1=ON Drivecon Inc. reserves the right to alter or amend the above information without notice // 29/59...
  • Page 30 Temperature of heat sink. °C MotorTemperature V4.16. Calculated motor temperature in percent of maximum Motor Power V4.17. Calculated actual power. % of nominal power of unit Drivecon Inc. reserves the right to alter or amend the above information without notice // 30/59...
  • Page 31 0 – 65535 min Forever. S6.7. HW settings InternBrake Res P6.7.1. Must not be changed. Not conn. Fan Control P6.7.2. Must not be changed. First start Drivecon Inc. reserves the right to alter or amend the above information without notice // 31/59...
  • Page 32 State of board in slot B Program version E6.8.6.4.2. Program version of board in slot B 10501.4 E6.8.6.5. E: No board S6.8.7. Debug Not used S6.9. Power monitor Drivecon Inc. reserves the right to alter or amend the above information without notice // 32/59...
  • Page 33 Pressing the Enter button for about 2 to 3 seconds resets the whole fault history. Drivecon Inc. reserves the right to alter or amend the above information without notice // 33/59...

  • Page 34: Factory Default Parameters

    P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 34/59...
  • Page 35 P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 35/59...
  • Page 36 P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 36/59...
  • Page 37 P 2.3.28 DeadTime Comp 2200 P 2.3.28 DeadTime Comp 2200 P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 37/59...

  • Page 38: Factory Default Parameters For 120Hz Motors

    P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 38/59...
  • Page 39 P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 39/59...
  • Page 40 P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 40/59...
  • Page 41 P 2.3.28 DeadTime Comp 2200 P 2.3.28 DeadTime Comp 2200 P 2.3.29 DeadTimeCurrLim P 2.3.29 DeadTimeCurrLim P 2.3.30 Brake Chopper P 2.3.30 Brake Chopper Drivecon Inc. reserves the right to alter or amend the above information without notice // 41/59...

  • Page 42: Speed Supervision Settings

    SSU Overspeed Limit (F66): maximum setting of overspeed limit is 1.4×maximum speed of direction S2. Fault will be detected if overspeed limit is set over that value. When a fault is detected the drive is prevented from running. Drivecon Inc. reserves the right to alter or amend the above information without notice // 42/59...

  • Page 43: Standard Settings

    Drive with maximum speed. The motion must stop after full speed is reached. fault F64 (Over speed) is activated Set rotary switch S1/S3 back to original value. Drivecon Inc. reserves the right to alter or amend the above information without notice // 43/59...

  • Page 44: Settings For Non-Standard Cases

    2400Hz + 25% = Correct switch settings are S2-4=ON 3000Hz. and S3=4. Encoder with 600 ppr or over needs both encoder channels connected. Drivecon Inc. reserves the right to alter or amend the above information without notice // 44/59...

  • Page 45: Synchro Function

    (braking times) between drives can cause large displacement errors, especially braking from full speed (in fault case), and could lead to hazardous situations. Multicare and Synchro functions must not be used together. Drivecon Inc. reserves the right to alter or amend the above information without notice // 45/59...

  • Page 46: Start-Up

    There is no position difference between hooks, with smooth driving or with lots of accelerations and decelerations. − V2.4.10.1 Max Pos Error in the master drive doesn’t show any constant position error. Drivecon Inc. reserves the right to alter or amend the above information without notice // 46/59...

  • Page 47: Optic Cable Connections

    Check that Ramp time and Stop method especially after acceleration, parameters P2.1.10, P2.1.11 and P2.2.20 deceleration or stopping. have similar value in every drive. Drivecon Inc. reserves the right to alter or amend the above information without notice // 47/59...

  • Page 48: Multicare Function

    Read “Ain Value” (V2.1.12.3) and use this value (about 9 V) for speed correction calibratation – set “Max Value Volt” (P2.1.12.5, both drives) equal to received “Ain Value” – this value is likely the same for both drives. Drivecon Inc. reserves the right to alter or amend the above information without notice // 48/59...

  • Page 49: Test Run Without Load

    Repeat the same test with the other hoist. Check both hoists operate normally (in tandem mode and single mode) when reaching the slow-down and end stop limit in both directions. Drivecon Inc. reserves the right to alter or amend the above information without notice // 49/59...

  • Page 50: Start-Up Procedure

    Check motor operation (acceleration, deceleration and braking): accelerate to full speed direction S1, change to full speed direction S2 and full speed direction S1 again and stop. Drivecon Inc. reserves the right to alter or amend the above information without notice // 50/59...

  • Page 51: Functional Test Run For Ssu

    Make sure all remarks and setting values are recorded. It is recommended to store the parameter settings in file User parameters, see chapter “User parameters”. Drivecon Inc. reserves the right to alter or amend the above information without notice // 51/59...

  • Page 52: Troubleshooting

    The drive includes an automatic fault reset operation; the fault code stays on the display until the fault is removed and the controller released back to 0-position. Some of the fault codes require to switch the power off before run is possible. Drivecon Inc. reserves the right to alter or amend the above information without notice // 52/59...
  • Page 53 In case of temporary supply voltage break, reset the fault and start again. Check mains input. mains supply voltage interrupted If mains supply is correct, an internal failure has Drivecon Inc. reserves the right to alter or amend the above information without notice // 53/59...
  • Page 54 Check: long duration overload motor parameters lowered cooling u/f curve settings high environment temperature motor loading brake operation inverter heatsink inverter cooling fan operation Drivecon Inc. reserves the right to alter or amend the above information without notice // 54/59...
  • Page 55 Reset: switch power off and restart after the lamps of Fault relay is bypassed keypad are off. Check: ES and RDY external connections OK input operation change SSU board Drivecon Inc. reserves the right to alter or amend the above information without notice // 55/59...

  • Page 56: Fault Time Data Record

    1=Ready 0=Not Running 1=Run T.11 Direction 0=Off 1=On Fault 0=No 1=Yes T.12 Warning 0=No 1=Yes At reference 0=No 1=Yes T.13 0-speed 0=Not Zero Speed Drivecon Inc. reserves the right to alter or amend the above information without notice // 56/59...

  • Page 57: Fault Counter

    Motor load is over adjusted value Check: Overweight alarm Overweight limit value A 83 Motor load is under adjusted value Check: Slack cable alarm Slack cable limit value Drivecon Inc. reserves the right to alter or amend the above information without notice // 57/59...

  • Page 58: Troubleshooting Table

    VOLTAGE L1-L2 L1-L3 L2-L3 NOMINAL CURRENT PHASE-TO-PHASE Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω Ω VOLTAGE PHASE-TO-GROUND MEASURED CONTROL VOLTAGE Drivecon Inc. reserves the right to alter or amend the above information without notice // 58/59...

  • Page 59: Service

    (minimum 100kΩ Ω Ω Ω 2W). Discharging will take several minutes and resistor will get hot. Measure the voltage before touching the capacitor terminals. Drivecon Inc. reserves the right to alter or amend the above information without notice // 59/59...
  • Page 66 ©2007 Drivecon Inc. 9505 72nd Ave.Suite 100 Pleasant Prairie, WI 53158 800-374-8266 www.drivecon.com...

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