Drivecon XT Series Manuale utente

Service Manual

9505 72nd Ave. Suite 100

Phone: 1-800- 374-8266

Fax: (262) 947-0526

www.drivecon.com

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Service Manual

Rev 6.0 with software Ind2V101

    

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

// 2/59

Service Manual

Rev 6.0 with software Ind2V101





 Read the Instructions supplied with the hoist before installation, commissioning and servicing

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

 Keep the instructions in a safe place for future reference.

1GENERAL ............................................................................................................................................................................. 5

1.1Technical data................................................................................................................................................................ 5

1.2Type mark coding........................................................................................................................................................... 6

1.3Basic description............................................................................................................................................................ 6

1.4Functional description .................................................................................................................................................... 6

1.5Description of the control modes.................................................................................................................................... 7

1.5.1EP2-control............................................................................................................................................................. 8

1.5.2EP3-control............................................................................................................................................................. 8

1.5.3MS4-control ............................................................................................................................................................ 8

1.6Mechanical brake control ............................................................................................................................................... 9

1.7EMC ............................................................................................................................................................................... 9

2INSTALLATION .................................................................................................................................................................. 10

2.1Power cabling............................................................................................................................................................... 10

2.1.1Shielded motor cable............................................................................................................................................ 10

2.1.2Double collectors.................................................................................................................................................. 10

2.1.3 4

Ground Conductor ............................................................................................................................................... 10

2.1.4Cable selection..................................................................................................................................................... 10

2.1.5Cable protection ................................................................................................................................................... 10

2.1.6 Cable length............................................................................................................................................................... 11

2.1.7 Du/dt filters................................................................................................................................................................ 11

2.2Signal cabling............................................................................................................................................................... 11

2.2.1Shielded signal cable............................................................................................................................................ 11

2.2.2Reference signals................................................................................................................................................. 11

2.2.3Sensor bearing ..................................................................................................................................................... 11

2.2.4Encoder ................................................................................................................................................................ 11

2.3EMC compatible grounding.......................................................................................................................................... 12

2.3.1Construction connections ..................................................................................................................................... 12

2.3.2Cable connections................................................................................................................................................ 12

2.3.3Shielded control cables ........................................................................................................................................ 12

3COMPONENTS ................................................................................................................................................................... 13

3.1Inverter ......................................................................................................................................................................... 13

3.1.1Power supply unit (PSU) ...................................................................................................................................... 14

3.1.2Control unit (CSU) ................................................................................................................................................ 14

3.1.3Basic I/O board (Slot A)........................................................................................................................................ 15

3.1.4Relay / Thermistor board (Slot B)......................................................................................................................... 15

3.1.5SSU Speed Supervision board (Slot C)................................................................................................................ 16

3.1.6I/O Extension board (Slot D)................................................................................................................................. 16

3.1.7System bus board (Slot E, option)........................................................................................................................ 17

3.2Control voltage transformer.......................................................................................................................................... 17

3.3Speed sensors ............................................................................................................................................................. 17

3.3.1Sensor bearing ..................................................................................................................................................... 17

3.3.2Encoder ................................................................................................................................................................ 18

3.3.3Proximity switch.................................................................................................................................................... 20

3.3.4Buffer amplifier KAE248 ....................................................................................................................................... 21

3.4Brake controllers .......................................................................................................................................................... 21

3.4.1REC12 .................................................................................................................................................................. 21

3.4.2ESD141 ................................................................................................................................................................ 22

4PARAMETER ADJUSTMENTS .......................................................................................................................................... 23

4.1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

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Service Manual

Rev 6.0 with software Ind2V101

4.2Storing and restoring parameters................................................................................................................................. 24

4.2.1User parameters................................................................................................................................................... 24

4.2.2Default parameters ............................................................................................................................................... 25

4.2.3Keypad settings .................................................................................................................................................... 25

4.2.4Factory settings .................................................................................................................................................... 25

5PARAMETER DESCRIPTIONS .......................................................................................................................................... 26

6FACTORY DEFAULT PARAMETERS ............................................................................................................................... 34

6.1Factory default parameters for 100Hz motors.............................................................................................................. 34

6.2Factory default parameters for 120Hz motors.............................................................................................................. 38

7SPEED SUPERVISION SETTINGS .................................................................................................................................... 42

7.1Standard settings ......................................................................................................................................................... 43

7.1.1Settings for sensor bearing................................................................................................................................... 43

7.1.2Settings for pulse wheel speed sensor or encoder (24 ppr) ................................................................................. 43

7.2Functional test run for SSU.......................................................................................................................................... 43

7.3Settings for non-standard cases .................................................................................................................................. 44

8SYNCHRO FUNCTION ....................................................................................................................................................... 45

8.1Function ....................................................................................................................................................................... 45

8.2Start-up ........................................................................................................................................................................ 46

8.3Optic cable connections............................................................................................................................................... 47

8.4Troubleshooting ........................................................................................................................................................... 47

9MULTICARE FUNCTION .................................................................................................................................................... 48

9.1Connections ................................................................................................................................................................. 48

9.2Setup............................................................................................................................................................................ 48

9.3Test run without load.................................................................................................................................................... 49

10START-UP PROCEDURE ............................................................................................................................................... 50

10.1Visual checks ............................................................................................................................................................... 50

10.2Checks before the first test run .................................................................................................................................... 50

10.3Test run without load.................................................................................................................................................... 50

10.3.1Functional test run for SSU .................................................................................................................................. 51

10.4Test run with load......................................................................................................................................................... 51

10.5Test run with overload.................................................................................................................................................. 51

10.6After the test run........................................................................................................................................................... 51

11TROUBLESHOOTING .................................................................................................................................................... 52

11.1Field repair actions....................................................................................................................................................... 52

11.2Typical functional problems.......................................................................................................................................... 52

11.3Inverter fault codes....................................................................................................................................................... 52

11.3.1Fault time data record........................................................................................................................................... 56

11.3.2Fault Counter........................................................................................................................................................ 57

11.4Inverter Alarm codes .................................................................................................................................................... 57

12TROUBLESHOOTING TABLE ....................................................................................................................................... 58

13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

4/59

Service Manual

Rev 6.0 with software Ind2V101

This manual rev 6.0 is for inverter rev 5.1 with software Ind2V101.





 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 multimeter 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. Electrostatic discharge may cause damage or destroy the

IC-circuits.





 Check all ventilation holes are clear and unobstructed.





 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.





 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

5/59

Service Manual

Rev 6.0 with software Ind2V101

1 GENERAL

1.1 Technical data

Power class 4004 4005 4009 4012 4016 4022 4031 4038 4045 4061 4072 4087 4105

Horsepower 2 2 5 7.5 10 15 20 25 30 40 50 60 75

Output current In (A) 4 5.4 9 12 16 22 31 38 45 61 72 87 105

Max. current 1min (A) 6.0 8.1 13.5 18 24 33 46 57 67 91 108 130 157

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 s

... 100% (s

= 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.

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

6/59

Service Manual

Rev 6.0 with software Ind2V101

1.2 Type mark coding

XT drives can be summarized as a "crane hoisting and traveling 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 Power class current handling type code

See technical specifications

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

Inverter has many advantages and offers many new features, when compared to other inverter based systems, which might be

used in crane applications.

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.

Crane user interface 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 Includes the brake contactor for disk brakes. Includes also DC-rectifier.

Electrical Braking Includes a braking transistor and a braking resistor.

Control methods Can be controlled by

the electronic potentiometer control with 2-step or 3-step pushbuttons,

the multistep control with 2-4-step controllers.

Limit switch functions Built-in slowdown (S11, S21) and stop limit switch (S12, S22) functions for both running directions.

Speed supervision Inverter 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 Includes a motor thermal protection, which is based on motor temperature measurement by Klixon placed in motor windings. A

great number of other protections included are shown in the technical data.

Tested parameters Inverter includes tested parameters with different motors for all power ratings. This is a benefit, which makes every inverter

delivery a proven solution. The tested and pre-set motor parameters enable a quick start-up in crane commissioning.

1.4 Functional description

Operation when power is switched on

- Stop limit switches S12 & S22 and slow down limit switches S11 & S21 are assumed to be normally closed, as well as the

emergency stop button ES.

- The control voltage is supplied to terminal A16. 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.

- 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

7/59

Service Manual

Rev 6.0 with software Ind2V101

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. Motor accelerates according to the acceleration ramp setting to the selected speed.

- When the switch S1 (S2) opens motor 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, 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.

1.5 Description of the control modes

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 A11 S1 S1 S1

S2 A12 S2 S2 S2

OK A16 OK OK OK

DIA3 A13 AP AP MS2

DIA4 A14 Not used HOLD MS3

DIA5 A15 Not used not used MS4

DID1 D1 FWE FWE FWE

DID2 D2 S11 S11 S11

DID3 D3 S21 S21 S21

DID4 D4 S12 S12 S12

DID5 D5 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

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

8/59

Service Manual

Rev 6.0 with software Ind2V101

1.5.1 EP2-control

c_coep2a

A. Pushbutton / controller position

B. Speed

0) “decelerate to zero”

1) while starting “drive minimum speed”

while running “hold speed”

2) while running “accelerate”

while running at maximum speed “hold speed”

1.5.2 EP3-control

c_coep3a

A. Pushbutton / controller position

B. Speed

0) “decelerate to zero”

1) step 1 “drive minimum speed”

2) step 2 “hold speed”

3) step 3 while running “accelerate”

while running at maximum speed “hold speed”

1.5.3 MS4-control

c_coms4b

A. Controller position

B. Speed

0) “decelerate to zero”

1) step 1 “drive minimum speed”

2) step 2 “drive speed2”

3) step 3 “drive speed3”

4) step 4 “drive maximum speed”

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

9/59

Service Manual

Rev 6.0 with software Ind2V101

1.6 Mechanical brake control

Inverter 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. During a direction change, the brake is

kept open all the time. Inverter 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.

1.7 EMC

The abbreviated "EMC" stands for the Electromagnetic Compatibility. According to the European 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 All products fulfil the immunity requirements defined in the EN 61800-3

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

10/59

Service Manual

Rev 6.0 with software Ind2V101

2 INSTALLATION

2.1 Power cabling

2.1.1 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.

2.1.2 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.

2.1.3 4th Ground Conductor

According to NEC article 409, all new installations are required to include a dedicated 4

conductor for the purposes of making

a reliable ground connection for the crane. Without a reliable ground connection, the crane must rely on the wheels of the

crane to provide a connection to ground. In this method, the connection is unreliable and can cause premature aging of the

bridge wheels and in the worst case cause permanent damage to electronic components.

2.1.4 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 460V 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 4004 4005 4009 4012 4016 4022 4031 4038 4045

Max. motor cable length Ft 160 160 160 160 160 160 160 160 160

Motor wire size CMAA Class D 104

F AWG 14 14 14 14 12 10 8 8 6

Hoisting braking resistor wire

size CMAA Class D

104

F AWG 14 14 14 14 14 14 14 12 8

Traverse braking resistor wire

size CMAA Class D

104

F AWG 14 14 14 14 14 14 14 14 10

Power class 4061 4072 4087 4105

Max motor cable length Ft 160 160 240 240

Motor wire size CMAA Class D 104

F AWG 4 3 2 1/0

Hoisting braking resistor wire

size CMAA Class D

104

F AWG 8 4 4 3

Traverse braking resistor wire

size CMAA Class D

104

F AWG 10 8 8 6

2.1.5 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.

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