Page 3: Product Safety Information
This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of Magnetek. Parts of this product may be covered by one or more of the following patents: 6,598,859, 6,653,804, 6,956,339, 7,190,146, 7,841,583, 8,401,814, 8,669,724, and 8,686,670.
Page 4: Danger, Warning, Caution, And Note Statements
WA R N I N G Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or performance of the drive. DANGER, WARNING, CAUTION, and NOTE Statements DANGER, WARNING, CAUTION, and Note statements are used throughout this manual to emphasize important and critical information.
Page 5: Service Information
Unit 3 Bedford Business Centre Mile Road Bedford, MK42 9TW UK Phone: +44.1234.349191 Fax: +44.1234.268955 Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetek.com. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017...
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Page 7: Table Of Contents
Contents: Product Safety Information ............... . i-i DANGER, WARNING, CAUTION, and NOTE Statements .
Page 8 Keypad LED and Button Functions ............. 4-5 Parameters .
Page 9 Lower Limit/Upper Limit Bypass MFDI............5-24 Load Float .
Page 10 Digital Output (DO-A3) and S4IO Option Set-up ..........5-80 Profibus-DP Communication Option Card Set-up .
Page 11 Power Section Check ................6-30 Power Off Checks .
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Page 13: Chapter 1: Introduction
C h a p t e r Introduction...
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Page 15 WA R N I N G Do not touch any circuitry components while the main AC power is on. In addition, wait until the red “CHARGE” LED is out before performing any service on that unit. It may take as long as 5 minutes for the charge on the main DC bus capacitors to drop to a safe level.
Page 16: How To Use This Manual
® NOTE: If the IMPULSE •G+ & VG+ Series 4 is part of a Magnetek motor control panel, reference the control drawings, disregard this chapter, and turn to Chapter 4. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017...
Page 17: Introduction
7. For severe-duty applications (long lifts, for example) or with 75-HP-or-greater motors, ensure that the drive control system (including dynamic braking resistors) is adequately cooled, even though the ambient temperature limit is not exceeded. For more information, contact Magnetek. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017...
Page 18: Impulse®•G+ & Vg+ Series 4 General Specifications
® IMPULSE •G+ & VG+ Series 4 General Specifications Table 1-2: Specification Values and Information - Heavy Duty 230 V 460 V 575 V Rated Rated Rated Model Model Model Output Output Output Output Output Output (-G+/ (-G+/ (-G+/ Capacity Capacity Capacity Current...
Page 19 Table 1-3: Specifications for 230 V, 460 V, and 575 V Specification Specification Value and Information for All Models Certification UL, cUL, CSA, CE, RoHS Crane Duty Classification Rated for CMAA Crane Duty Class A - F only (or equivalent) Rated input power supply volts 3-phase 200 to 240 VAC 50/60 Hz for a 230 VAC-rated drive &...
Page 20: Ac Reactor Specifications
Specification Specification Value and Information for All Models Heatsink overtemperature Thermostat trips at 105°C (221°F) Torque limit selection Separate functions for FORWARD, REVERSE, REGEN; all selectable from 0–300% Stall prevention Separate functions for accel, decel, at-speed, and constant horsepower region Other protection features VG+: Speed deviation, overspeed, mechanical brake failure, lost output phase, failed-oscillator, PG-disconnect, roll-back detection, micro controller...
Page 21 Table 1-4: 230 V Class Model Number 230 V Part Number Maximum Amps of Reactor 2003-G+/VG+S4 REA230-1 2005-G+/VG+S4 REA230-1 2007-G+/VG+S4 REA230-2 2008-G+/VG+S4 REA230-2 2011-G+/VG+S4 REA230-3 2014-G+/VG+S4 REA230-3 2017-G+/VG+S4 REA230-5 2025-G+/VG+S4 REA230-7.5 2033-G+/VG+S4 REA230-10 2047-G+/VG+S4 REA230-15 2060-G+/VG+S4 REA230-20 2075-G+/VG+S4 REA230-25 2085-G+/VG+S4 REA230-30 2115-G+/VG+S4 REA230-40...
Page 22 Table 1-5: 460 V Class Model Number 460 V Part Number Maximum Amps of Reactor 4001-G+/VG+S4 REA460-1 4003-G+/VG+S4 REA460-2 4004-G+/VG+S4 REA460-3 4005-G+/VG+S4 REA460-5 4007-G+/VG+S4 REA460-5 4009-G+/VG+S4 REA460-5 4014-G+/VG+S4 REA460-7.5 4018-G+/VG+S4 REA460-10 4024-G+/VG+S4 REA460-15 4031-G+/VG+S4 REA460-20 4039-G+/VG+S4 REA460-25 4045-G+/VG+S4 REA460-30 4060-G+/VG+S4 REA460-40 4075-G+/VG+S4 REA460-50...
Page 23 Table 1-6: 575 V Class Model Number 600 V Part Number Maximum Amps of Reactor 5001-G+/VG+S4 REA575-1 5003-G+/VG+S4 REA575-2 5004-G+/VG+S4 REA575-3 5006-G+/VG+S4 REA575-5 5009-G+/VG+S4 REA575-10 5012-G+/VG+S4 REA575-10 5017-G+/VG+S4 REA575-15 5022-G+/VG+S4 REA575-20 & 25 5027-G+/VG+S4 REA575-30 5032-G+/VG+S4 REA575-30 5041-G+/VG+S4 REA575-40 5052-G+/VG+S4 REA575-50 5062-G+/VG+S4 REA575-60...
Page 24: S4If Interface Specifications
S4IF Interface Specifications ® IMPULSE •G+ & VG+ Series 4 is designed to interface with user input and output devices through the S4IF interface board. This eliminates the need for an additional interface relay or isolation circuitry. The S4IF comes in 24 VDC, 24 VAC (50/60 Hz), 42 to 48 VAC (50/60 Hz), and 120 VAC (50/60 Hz) options.
Page 25 Table 1-9: S4IO Ratings I1-I4 O1-O6 S4IO Model Current Voltage Frequency Voltage (max) (max) S4IO-120A60* 120 VAC 50/60 Hz 250 VAC S4IO-48A60 42–48 VAC 50/60 Hz (48VAC for CE)/ 1.0 A 30 VDC S4IO-24A60 24 VAC 50/60 Hz * Not certified for CE compliance. IMPULSE®•G+ &...
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Page 27: Chapter 2: Installation
C h a p t e r Installation...
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Page 29 WA R N I N G ® •When preparing to mount the IMPULSE •G+ & VG+ Series 4 drive, lift it by its base. Never lift the drive by the front cover, as doing so may cause drive damage or personal injury. •Mount the drive on nonflammable material.
Page 30: Impulse®•G+ & Vg+ Series 4 System Components And External Devices
® IMPULSE •G+ & VG+ Series 4 System Components And External Devices ® Standard IMPULSE •VG+ Series 4 Drive Components • PG-X3 Line Driver Encoder Card Optional Drive Components • DI-A3 Digital DC Input Card • DO-A3 Digital Output Card •...
Page 31: Long Time Storage
Inverter drives contain large bus capacitors that have the potential to be reformed. However, printed circuit boards also contain electrolytic capacitors that may not function after several years without power. Magnetek recommends replacing the PCBs should the drive’s functionality not be restored after bus cap reforming. Contact Magnetek Service for questions.
Page 32 If any abnormal indications occur during this process, it is recommended that the process be repeated. Otherwise, this completes the capacitor reforming procedure. Figure 2-1: Long Time Storage IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017...
Page 33: Installing The Drive
Installing the Drive ® To install IMPULSE •G+ & VG+ Series 4: 1. Ensure the drive will be used in a proper environment. Refer to page 1-5. ® 2. Review “IMPULSE •G+ & VG+ Series 4 Terminal Block Configuration” on page 3-12. 3.
Page 34 Separate control drive circuit and power circuit wiring on the terminal block strip. 7. Obtain the appropriate hardware for mounting. 8. Mount the subpanel or surface to which you are mounting the drive (contact Magnetek if advice is needed in regards to mounting drives, especially for larger drives).
Page 35: Multiple Drive Installation (Side-By-Side Installation)
Multiple Drive Installation (Side-by-Side Installation) Models 2003 to 2075, 4001 to 4039, and 5001 to 5027 can take advantage of Side-by-Side installation. When mounting drives with the minimum clearing of 0.08 inches (2 mm) according to Figure 2-4, set parameter L08-35 to 1 while considering derating. A –...
Page 36: Drive Derating Data
In order to ensure reliable drive overload protection, set parameters L08-12 and L08-35 according to the installation conditions. Contact Magnetek for derating curves. IP00/Open-Chassis Enclosure Drive operation between -10°C to +60°C (14°F to 140°F) allows CMAA Class F continuous current...
Page 37 Figure 2-9 Table 2-1: Enclosure Dimensions - 230 V Drives Dimensions (in) Drive Model Total Number Loss Figure (-G+/VG+S4) (lbs) (W)* 2003 5.51 10.24 5.79 4.80 9.76 0.06 1.50 0.20 2005 5.51 10.24 5.79 4.80 9.76 0.06 1.50 0.20 2007 5.51 10.24 5.79...
Page 38 Table 2-2: Enclosure Dimensions - 460 V Drives Drive Dimensions (in) Total Model Loss Number Figure (lbs) (W)* (-G+/VG+S4) 4001 5.51 10.24 5.79 4.80 9.76 0.06 1.50 0.20 4003 5.51 10.24 5.79 4.80 9.76 0.06 1.50 0.20 4004 5.51 10.24 5.79 4.80 9.76...
Page 39 Table 2-3: Enclosure Dimensions - 575 V Drives Dimensions (in) Drive Model Total Number Loss Figure (-G+/VG+S4) (lbs) (W)* 5001 5.51 10.24 5.79 4.80 9.76 0.06 1.50 0.20 48.7 5003 5.51 10.24 5.79 4.80 9.76 0.06 1.50 0.20 81.9 5004 5.51 10.24 6.46...
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Page 41: Chapter 3: Wiring
C h a p t e r Wiring...
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Page 43: Impulse®•G+ & Vg+ Series 4 Wiring Practices
® IMPULSE •G+ & VG+ Series 4 Wiring Practices WA R N I N G Before you wire the drive, review the following practices to help ensure that your system is wired properly. • Ensure that the encoder wiring is less than 300 feet unless fiber optic cables are used. •...
Page 44 • To reverse the direction of rotation, program B03-04 = 1 (exchange phases), or interchange any two motor leads (changing R/L1, S/L2, or T/L3 will not affect the shaft rotation direction) as well as encoder phasing (F01-02 = 0/1 or swapping A and A wires). •...
Page 45 <1> Set L08-55 to 0 when using an external dynamic braking option. ® Figure 3-1: IMPULSE •G+ & VG+ Series 4 Typical Connection Diagram IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017...
Page 46: Suggested Circuit Protection Specifications And Wire Size
Suggested Circuit Protection Specifications and Wire Size In order to comply with most safety standards, some circuit protective devices should be used ® between the incoming three-phase power supply and the IMPULSE •G+ & VG+ Series 4. These devices can be thermal, magnetic, or molded-case breakers (MCCB); or “slow-blow” type fuses such as “CCMR”...
Page 47 Table 3-2: Wire Sizing for 460 V Class 1, 4 Recommended Gauge (AWG) Inverse Time Continuous Time Delay Time Delay Molded/Case Circuit Ground Model # HD Input Input Fuse Input Fuse Control (-G+/VG+S4) Amps Class Breaker (A) Power Circuit Wiring Wiring Copper 14 to 10...
Page 48 Table 3-3: Wire Sizing for 575 V Class 1, 4 Recommended Gauge (AWG) Inverse Time Continuous Time Delay Time Delay Molded/Case Circuit Ground Model # HD Input Input Fuse Input Fuse Control (-G+/VG+S4) Amps Class Breaker (A) Power Circuit Wiring Wiring Copper 5001...
Page 49: Power Circuit Wiring Procedures
Power Circuit Wiring Procedures ® To wire the power circuit for IMPULSE •G+ & VG+ Series 4: 1. Run the three-phase power supply wires through an appropriate enclosure hole. 2. Refer to “Suggested Circuit Protection Specifications and Wire Size” on page 3-6, connect the three-phase power supply wires to a circuit protection system.
Page 50: Main Circuit Connection Diagram
Main Circuit Connection Diagram Figure 3-2: Connecting Main Circuit Terminals (2003 to 2075) (4001 to 4039) (5001 to 5027) Figure 3-3: Connecting Main Circuit Terminals (2085 and 2115) (4045 and 4060) (5032 and 5041) * Connect optional DBU to terminals B1 and – IMPULSE®•G+ &...
Page 51 Figure 3-4: Connecting Main Circuit Terminals (2145 to 2180) (4075 to 4112) (5052 to 5077) Figure 3-5: Connecting Main Circuit Terminals (2215 to 2415) (4150 to 4605) (5099 to 5200) * Connect optional DBU to terminals +3 and – IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017 3-11...
Page 52 Figure 3-6: Connecting Main Circuit Terminals 4810 and 41090 * Connect optional DBU to terminals +3 and – IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017 3-12...
Page 53: Terminal Block Configuration
Terminal Block Configuration Figure 3-7 and Figure 3-8 show the different main circuit terminal arrangements for the drive capacities. Figure 3-7: Main Circuit Terminal Block Configuration IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017 3-13...
Page 54 <1> Terminal block design differs slightly for models 2215 to 2415, 4180 to 4304, and 5099 to 5200. Figure 3-8: Main Circuit Terminal Block Configuration (continued) IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017 3-14...
Page 55: Insulation Barrier
Insulation Barrier Insulation barriers are packaged with drive models 4370 through 41090 to provide added protection between terminals. Magnetek recommends using the provided insulation barriers to ensure proper wiring. Refer to Figure 3-9 for instructions on placement of the insulation barriers.
Page 56 Figure 3-10: Grounding Figure 3-11: Motor Grounding IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017 3-16...
Page 57: Interface Circuit Board
Interface Circuit Board S4IF DIP Switches and Jumper Figure 3-12: S4IF DIP Switches and Jumper Locations for 120 VAC, 42–48 VAC, and 24 VAC) Figure 3-13: S4IF DIP Switches and Jumper Locations for 24 VDC IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017 3-17...
Page 58: Dip Switches
Table 3-5: Terminal and Wire Specifications Wire Range Terminal Terminal Clamping Torque Symbol Screw Lb-in (N-m) AWG (mm 26 to 16 4.2 to 5.3 (Stranded: 0.14 to 1.5) (0.5 to 0.6) (Solid: 0.14 to 1.5) Dip Switches DIP Switches are described in this section. The functions of the DIP switches are shown in the table below.
Page 59: Sinking/Sourcing Mode Selection For Safe Disable Inputs
Sinking/Sourcing Mode Selection for Safe Disable Inputs Use jumper S3 on the Interface Board to select between Sink mode, Source mode, or external power for the Safe Disable inputs H1 and H2 (as shown in Table 3-7). Jumper S3 is also used to disable the Safe Disable inputs H1 and H2, with the jumpers in place the Safe Disable inputs are disabled.
Page 60: Control Circuit Terminals
Control Circuit Terminals The table below outlines the functions of the control circuit terminals. Terms: • Multi-Function Digital Input (MFDI) • Multi-Function Digital Output (MFDO) • Multi-Function Analog Input (MFAI) • Multi-Function Analog Output (MFAO) Table 3-8: Control Circuit Terminals Classification Terminal Signal Function...
Page 61: S4If Control Circuit Terminal Diagrams
Classification Terminal Signal Function Description Signal Level -10 to +10V, 2 mA Multi-function analog output (H04- MFAO 1 0 to +10V, 2 mA 01 to H04-03) 4 to 20 mA Analog Output Signal Analog Common Analog signal common Multi-function analog output 2 -10 to +10V, 2 mA MFAO 2 (H04-04 to H04-06)
Page 62: Safe Torque Off
Safe Torque Off The Safe Disable inputs provide a stop function in compliance with “Safe Torque Off” as defined in IEC/EN 61800-5-2. Safe Disable inputs have been designed to meet the requirements of the ISO/EN 13849-1, Category 3 PLd, and IEC/EN 61508, SIL2. Two Safe Disable inputs and one EDM output Inputs/Outputs according to ISO/EN 13849-1 Cat.
Page 63 Figure 3-16: Safe Torque Off Block Diagram IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017 3-23...
Page 64: Wiring The Encoder Circuit
Do not connect the encoder to the motor with roller chain or gear drive. If unable to direct-couple the encoder, use a timing belt to drive the encoder. (Contact Magnetek for encoder kits.) Also, do not connect the encoder to the low-speed shaft of a speed reducer.
Page 65: Encoder Wiring Diagrams And Information
Encoder Wiring Diagrams and Information Encoder 1: Install in option port CN5-C Encoder 2: Install in option port CN5-B. Figure 3-17: PG-X3 Encoder Card Wiring Table 3-10: Encoder Wiring Encoder Signal Wire Color PG-X3 Terminal +5 to 15 VDC Black Blue Gray Green...
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Page 67: Chapter 4: Getting Started
C h a p t e r Getting Started...
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Page 69: Overview
Overview ® With its easy-to-use keypad and X-Press Programming, the IMPULSE •G+ & VG+ Series 4 makes it easy to get up and running right away. In addition to explaining the keypad and X-Press Programming, this chapter explains how to view the scroll settings, get into the programming mode, and program speeds.
Page 70: Using The Keypad
Because of the additional potential hazards that are introduced when any drive is operated locally, we advise you to avoid operating it this way. If the drive is operated locally, be aware that the crane or hoist will move when the RUN button is pressed. Contact Magnetek with any questions.
Page 71: Keypad Led And Button Functions
• Selects a menu item to move between displays. • Displays the phone number for the Magnetek Service department. • Switches drive control between the operator (LOCAL) and an external source (REMOTE) for the Run command and frequency reference. *2 •...
Page 72: Parameters
The terms “constant” and “parameter” have the same meaning. Before shipping the drive, Magnetek programmed initial settings in the drive’s software so that most, if not all, of the crane system requirements are supported. However, if it is necessary to change the initial settings, Magnetek recommends that only qualified crane system technicians program the drive.
Page 73: Parameter Modes
Parameter Modes All parameters are organized under four modes: Operation Mode Drive operation is enabled. Drive status LED is lit. Programming Mode Parameter access levels, control method, motion, speed reference, and passwords are selected. Parameters are set/read. Items to be set/read vary depending on the access level setting. Auto-Tuning Mode Automatically calculates and sets motor parameters to optimize drive performance.
Page 74 Group Function Monitor Fault Trace Monitor Fault History Maintenance Control Monitor Initialization Parameters Initialize User-Defined Parameters Preset References Reference Limits Application Sequence/Reference Source Acceleration/Deceleration Jump Frequencies Quick Stop Reverse Plug Simulation Micro-Speed End of Travel Limits Phantom Stop Load Sharing/Torque Following Klixon Hook Height Measurement Electronic Programmable Limit Switches (EPLS)
Page 75: Initialization Set-Up
Initialization Set-up Parameter Access Level (A01-01) his parameter allows the “masking” of parameters according to user level. See the following table: Table 4-1: Parameter Access Level Settings Setting Description Operation Only Access to only parameters A01-01, A01-06, and all U monitor parameters. User Parameters Accesses parameters selected by OEM or installer (A02-01 to A02-32).
Page 76: X-Press Programming
X-Press Programming™ X-Press Programming automatically configures several commonly used parameters and features when Control Method (A01-02), Motion (A01-03), or Speed Reference (A01-04) are programmed. These parameters are also added to the Quick-Set menu for fast parameter modification. Reference tables 4-6, 4-7, and 4-8 for X-Press Programming defaults.
Page 77 WA R N I N G When changing A01-03 or A01-04, MFDI, MFDO, and speed reference parameters will be overwritten by X-Press Programming (Table 4-6, 4-7, or 4-8 on pages 4-12, 4-13, and 4-14). All parameter settings must be verified for proper operation. Table 4-5: X-Press Programming I/O Quick Reference A01-04 = Terminal S1...
Page 78 Parameters Changed by X-Press Programming Table 4-6: Traverse (A01-03= 0) for G+ and VG+S4 Models A01-04 = Parameter Description 2-Speed 3-Speed 5-Speed 2-Step 3-Step Uni- Indus- RS485/ Bi-Polar Multi- Multi- Multi- Infinitely Infinitely Polar trial RDSI Analog Step Step Step Variable Variable Analog...
Page 79 Table 4-7: Hoist - Standard Hoist (A01-03 = 1) for G+S4 Models A01-04 = Parameter Description 2-Speed 3-Speed 5-Speed 2-Step 3-Step Uni- Indus- RS485/ Bi-Polar Multi- Multi- Multi- Infinitely Infinitely Polar trial RDSI Analog Step Step Step Variable Variable Analog Coms Coms B01-01...
Page 80 Table 4-8: Hoist NLB (A01-03 = 2) for VG+S4 Models A01-04 = Parameter Description 2-Speed 3-Speed 5-Speed 2-Step 3-Step Uni- Indus- RS485/ Bi-Polar Multi- Multi- Multi- Infinitely Infinitely Polar trial RDSI Analog Step Step Step Variable Variable Analog Coms Coms B01-01 Speed 1 20.00...
Page 81: Initialize Parameters (A01-05)
Initialize Parameters (A01-05) Use this parameter to reset the inverter to its factory default settings. Table 4-9: Initialize Parameter Settings Setting Description No Initialization (factory default) 1110 User Default (defaults) Resets parameters to the values saved by the user as User Settings. User Settings are stored when parameter O02-03 is set to “1: Set defaults”.
Page 82: User Parameters (A02-01 Through 32)
User Parameters (A02-01 through 32) The user can select up to 32 parameters for quick-access programming. By setting the user access level (A01-01) to “User Program”, only the parameters selected in function A2 can be accessed by the user. To assign a parameter as a user parameter, go to the A2 level in the initialize menu. Once the A2 parameters are set and A01-01 is programmed to “User Program”, only the parameters visible in the program menu will be assigned to an A2 parameter.
Page 83: Auto-Tuning
Ideally, perform a standard Auto-Tune with the motor uncoupled from the load. When the motor cannot be decoupled, perform a static or non-rotating Auto-Tune. NOTE: Contact Magnetek’s service department if an auto-tune can not be performed. Table 4-11: Auto-Tuning Parameter Settings Parameter Display...
Page 84: Standard Auto-Tune (T01-01 = 0) Instructions
Parameter Display Description Default Model Sets the no-load current for the motor. After setting the motor capacity to T01-02 and the motor rated current to T01-04, this parameter will automatically T01-09* No-Load Current display the no-load current for a standard 4 pole motor. Enter the no-load current as indicated on the motor test report or motor nameplate.
Page 85: Non-Rotational Auto-Tune (T01-01 = 1) Instructions
Non-Rotational Auto-Tune (T01-01 = 1) Instructions ® A non-rotational Auto-Tuning method has been implemented into the IMPULSE •VG+ Series 4 drive which allows for Auto-Tuning without decoupling the motor. This method will require a short movement of the crane subsequent to the non-rotational Auto-Tune process which allows the drive to calibrate the Motor Rated Slip and No-Load Current.
Page 86: Terminal Resistance Auto-Tune (T01-01 = 2) Instructions
Terminal Resistance Auto-Tune (T01-01 = 2) Instructions This is a non-rotational Auto-Tuning method for the IMPULSE®•G+ Series 4 drive which allows for Auto-Tuning without decoupling the motor. This method is recommended for motors configured with the V/f control method when the motor horsepower and motor rated current are known.
Page 87: Chapter 5: Programming Advanced Features
C h a p t e r Programming Advanced Features...
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Page 89: Introduction
* Initial value is determined by X-Press Programming (Table 4-6, 4-7, or 4-8 on pages 4-12, 4-13, and 4-14). ** Consult Magnetek for frequencies above 150 Hz. IMPULSE®•G+ & VG+ Series 4 Instruction Manual – February 2017...
Page 90 Table 5-2: Multi-Step Speed Processing by Multi-Function Digital Input (B01-01–B01-16) Forward/ Multi-Step Multi-Step Multi-Step Multi-Step Fwd/Rev Jog Speed Reverse Speed 2 Speed 3 Speed 4 Speed 5 Fwd/Rev Inch Reference Terminal S1 or S2 H01-01–08 = 0 H01-01–08 = 1 H01-01–08 = 2 H01-01–08 = 3 H01-01–08 = 15, 16, 17, 18...
Page 91: Reference Limits
Reference Limits These parameters limit the frequency range as a percentage of maximum output frequency (E01- 04). If the lower limit is below the DC Inj Start Freq (D01-01), then operation will continue according to B03-05. An alternate upper limit frequency can be used during operation when a Multi-Function Digital Input (MFDI) is set to 59 (Alt F-Ref Up Lmt) and the MFDI is on.
Page 92: Sequence/Reference Source
Sequence/Reference Source B03-01 and B03-02 determine the source from where the frequency reference and RUN command are generated. Table 5-4: Sequence/Reference Source Parameter Settings Parameter Display Function Range Default B03-01 Ref Source 1 Source from where the frequency reference is generated. Operator Digital Operator Terminals...
Page 93: Stop Method
Stop Method B03-03 selects the stopping method suitable for the particular application. Table 5-5: Stop Method Parameter Settings Parameter Display Function Range Default Model B03-03 Stopping Method Determines stop method. 0, 1, 4, 6 G+: 0* VG+: 6* Decel to Stop (Fig 5-2) G+/VG+ Coast to Stop...
Page 94: Coast To Stop (B03-03=1)
Coast to Stop (B03-03=1) Upon removal of the FWD or REV run command, the motor starts to coast and the electric brake sets. Command Frequency Base Block Output Brake Output Figure 5-3: Coast to Stop Decel w/Timer (B03-03=4) NOTE: This option is only available in traverse motion. Upon run command removal, the motor decelerates to stop.
Page 95: Motor Rotation Change
Motor Rotation Change This parameter allows you to change the motor direction without changing the motor leads. Table 5-6: Motor Rotation Parameter Settings Parameter Display Function Range Default B03-04 Change Rotation Reverse motor direction 0, 1 Standard SwitchPhaseOrder Switch phase order (reverses the direction of the motor NOTE: To reverse the direction of rotation, program B03-04 = 1 (exchange phases), or...
Page 96 Table 5-9: LO/RE Run Select Parameter Settings Parameter Display Function Range Default B03-07 LO/RE RUN Sel Determines action after switching 0, 1 Run/Speed reference source. Cycle Extrn RUN If the run command is present at the time when the Run/Speed reference source is switched, it requires the run command to be removed and reapplied from the...
Page 97 Parameter Display Function Range Default B03-16 Run Source 2 Determines what the drive will use 0–3 for Run Reference. Enabled by MFDI programmed to IF. Operator Digital Operator Terminals Terminals • S4-IF Interface Card • S4-I AC Digital Input Option •...
Page 98: Acceleration/Deceleration
Acceleration/Deceleration Acceleration time sets the time necessary for the output frequency to accelerate from 0 Hz to maximum output frequency (E01-04). Deceleration time sets the time necessary for the output frequency to decelerate from the maximum output frequency (E01-04) to 0 Hz. Table 5-10: Acceleration/Deceleration Parameter Settings Parameter Display...
Page 99: Accel/Decel Time Switching Frequency
Accel/Decel Time Switching Frequency Accel/Decel times can be changed automatically without using multi-function inputs. When multi- function digital inputs are set for Accel/Decel selection, this command has priority over automatic change of Accel/Decel. Table 5-11: Accel/Decel Time Switching Frequency Parameter Settings Parameter Display Function...
Page 100 Figure 5-6: Jump Frequencies Field Forcing The Field Forcing function compensates the delaying influence of the motor time constant when changing the excitation current reference and improves motor responsiveness. Field Forcing is ineffective during DC Injection Braking. Table 5-13: Field Forcing Parameter Settings Parameter Display Function...
Page 101: Special Functions
Special Functions Table 5-14: Special Function Usage Access Level (A01-01) Advanced (2) NLB Hoist Motion (A01-02) Traverse (0) Standard Hoist (1) Function/Control Method (A01-03) V/f (0) OLV (2) FLV (3) V/f (0) OLV (2) FLV (3)     ...
Page 102: Quick Stop
Quick Stop™ The Quick Stop Function provides an automatic Alternate Deceleration at Stop. NOTE: The Quick Stop Deceleration time differs from the normal deceleration time and is applied only when the RUN command is removed. Table 5-15: Quick Stop Parameter Settings Parameter Display Function...
Page 103: Reverse Plug Simulation
Reverse Plug Simulation™ The Reverse Plug Simulation provides an automatic alternate deceleration time/acceleration time at a change direction command. The deceleration time and the acceleration time are set independently of the normal acceleration and deceleration times. NOTE: Reverse Plug Simulation is not available in MLB (standard) Hoist. Table 5-16: Reverse Plug Simulation Parameter Display...
Page 104: Micro-Speed
Micro-Speed™ Micro-Speed provides a reduced speed range operation for precise positioning. Enabled by a Multi- Function Input, it multiplies the normal speed reference by the Micro-Speed Gain. Two Micro-Speed Gains are available: Gain 1 (C02-01) and Gain 2 (C02-02). They can be adjusted and enabled independently.
Page 105: End Of Travel Limits
End of Travel Limits This function can automatically slow and stop a crane or hoist when it reaches the end of travel limits. Two types of limit inputs (slowdown and stop) are available in both travel directions. Inputs can be programmed through the S4IF card. Table 5-18: End of Travel Limits Parameter Settings Parameter Display...
Page 106: Phantom Stop
Phantom Stop The Phantom Stop allows quick identification of a faulted drive while stopping other drives with Phantom Stop enabled. The Phantom Stop feature is designed to stop the drive operation using the stopping method selected in C03-10 when a Phantom Fault input (H01-01–H01-08 = 5F or 63) is active.
Page 107: Klixon
other special functions. If this is not the case, each inverter may try to move or decelerate at a different speed placing extra strain on the drive train and potentially resulting in a speed deviation fault. NOTE: 1. The Limit Switch stopping method is not selectable in Load Sharing mode. If a Stop Limit is input, the output is turned off and the brake output will set immediately.
Page 108: Hook Height Measurement
Hook Height Measurement Hook Height Measurement provides a monitor parameter (U01-50) and analog output proportional to the hook’s current position between a home position and a limit position. Hook height programming is used in conjunction with the Electronic Programmable Limit Switch parameters. Reference Figure 5-10 for Hook Height configuration.
Page 109: Electronic Programmable Limit Switches (Epls)
Electronic Programmable Limit Switches (EPLS) Using the motor revolutions (U01-51) from the Height measurement function, it is possible to program UL1, UL2, LL1, and LL2 positions without the use of rotary limit switches. When C03-16, C03-17, C03-18, or C03-19 has a value other than 0, the EPLS function will be enabled. Height measurement must be correctly setup before using EPLS.
Page 110: Lower Limit/Upper Limit Bypass Mfdi
Table 5-25: Monitor Values at Hook Height Home Position C03-15 = 0 C03-15 = 1 C03-14 U01-51 U01-50 U01-50 100% C03-13 100% 100% C03-13 100% 100% Lower Limit/Upper Limit Bypass MFDI The Limit Bypass allows for the following without the use of jumpers or re-programming of the drive parameters: 1.
Page 111 Figure 5-11: Upper Limit (UL1) Figure 5-12: Upper Limit 2 (UL2) Figure 5-13: Lower Limit 1 (LL1) Figure 5-14: Lower Limit 2 (LL2) IMPULSE®•G+ & VG+ Series 4 Instruction Manual – February 2017 5-25...
Page 112: Load Float
Load Float When Load Float (C08-10) is enabled, it maintains the motor shaft at a stationary position with brake open. The Load Float 2 (MFDI=35) function triggers the drive to go into Load Float for the time set in C04-01. During Load Float, the drive will open the brake and hold the motor at a zero position. A FWD or REV run command will take priority over this function.
Page 113: Olv And Flv Operation (A01-02 = 02 And 03)
OLV and FLV Operation (A01-02 = 02 and 03) ® When using Load Check II in Open Loop Vector or Flux Vector control method, the IMPULSE •G+ and VG+ Series 4 will compare the motor torque readings (U01-09) to values stored during the Load ®...
Page 114 NOTE: If an application requires Load Check to be bypassed, an MFDI may be programmed to 69 (N.O.) or 6A (N.C.) NOTE: Upon completion of the Load Check set-up process, the drive will automatically set C05-01 to 1. NOTE: If an error occurs during the Load Check set up, the load being lifted causes current or torque to exceed 250%.
Page 115 Parameter Display Function Range Default C05-13 I/T Level 05 Current/Torque values detected during LC 0–250% set up for Zone 05 C05-14 I/T Level 06 Current/Torque values detected during LC 0–250% set up for Zone 06 C05-15 I/T Level 07 Current/Torque values detected during LC 0–250% set up for Zone 07 C05-16...
Page 116: Swift-Lift™ & Ultra-Lift
Swift-Lift™ & Ultra-Lift™ Swift-Lift/Ultra-Lift provides additional productivity by allowing a crane or hoist to quickly move into position. The feature enables the motor to spin faster than the base speed when the load is less than 100% of the rated capacity. Ultra-Lift determines the torque required for the load, calculates the maximum safe speed, and automatically accelerates to this speed.
Page 117 Parameter Display Function Range Default Model C06-05 SL REV Current (V/f) Output Current/Torque < C06- 0–100% G+/VG+ 05 to enable Swift-Lift SL REV Torque (OLV) Reverse. Not used with UL REV Torque (FLV) Adaptive UL. C06-06 SL Enabling Spd (V/f and Fout >...
Page 118: Configuring The Swift-Lift & Ultra-Lift Function
Configuring the Swift-Lift & Ultra-Lift Function For 2, 3, 5-Speed Multi-Step (A01-04 = 0, 1, or 2): 1. Set C06-01= 1–4 to enable the Swift-Lift & Ultra-Lift Function, 1 = Enable Automatic, 2 = Enable by Multi-Function Digital Input (MFDI), 3 = Enable Adaptive (Ultra-Lift Only), 4 = Adaptive by MFDI (Ultra-Lift Only).
Page 119: Torque Limit
Torque Limit ® IMPULSE •G+ and VG+ Series 4 drives dynamically control the torque output of the motor while running. The Torque Limit Function limits the amount of torque the motor is capable of producing in Open and Closed loop vector control. •...
Page 120 Parameter Display Function Range Default Model C07-05 T-Lim FWD Gain Torque Limit gain in FWD direction 0.00–2.55 1.25 G+/VG+ when MFDI = 14 is ON. Gain is applied to C07-01. If T-Lim by Analog Input is used, gain is applied to post-scaled/biased input.
Page 121: Anti-Shock
Anti-Shock ® Anti-Shock is a Hoist NLB feature on the IMPULSE •VG+ Series 4 drive in the Flux Vector control method. The torque output of the hoist is continuously monitored, and when it increases above a threshold (C07-15 and C07-16), the hoist automatically decelerates and waits for the torque to stabilize before smoothly re-accelerating (C07-17 and C07-18).
Page 122 Table 5-31: Anti-Shock Parameter Settings Parameter Display Function Range Default C07-12 Anti-Shock Enables or disables the Anti-Shock 0–2 function. Disabled Anti-Shock is disabled always. Enabled Anti-Shock is enabled always. Enbl, Not In Disables Anti-Shock if Micro-Speed is MSpd enabled. C07-13 Enabling Freq Anti-Shock is disabled until the output 0.0–60.0 Hz...
Page 123: No-Load Brake Hoist (Vg+)
No-Load Brake Hoist (VG+) The No-Load Brake Hoist mode provides a start and stop sequence designed specifically for No- Load Brake Hoists. This mode is enabled automatically when the Motion is set to NLB Hoist (A01-03 = 2). This will also automatically set the Stopping Method to No-Load Brake (B03-03 = 6). Start The start sequence begins by building up torque in the motor to a predefined level within the C08-01 (Torque Compensation Time) timer.
Page 124 If the stored value is less than the programmed value in C08-03 (Minimum Brake Release torque), C08-03 is used as the next brake release value. If the feature must be disabled, C08-03 will override C08-16 if it is a greater value. Dual Brake Feature The Dual Brake feature is designed for hoist systems with redundant holding brakes.
Page 125 Table 5-32: No Load Brake Parameter Settings Parameter Display Function Range Default Model C08-01 Torque Comp Time Amount of time for the Torque 0.00–2.55 sec 1.00 Comp value to reach 300%. C08-02 IFB OK Time Sets the amount of time to look for 0.00–2.55 sec 1.00 the current feedback to be OK...
Page 126 Parameter Display Function Range Default Model C08-14 Brake Hold Speed The frequency the drive outputs to 0.0–25.5% push against the brake for brake proving at start as well as the frequency the drive continues to output until Brake Set Delay Timer expires or the Brake Answerback MFDI is removed.
Page 127: E-Lift (Vg+)
Flux Vector control. Always follow instructions given in the E-Lift setup instructions, and utilize extreme caution when operating a hoist in E-Lift mode. Stop the hoist if any undesired motion occurs and contact Magnetek for additional assistance. D A N G E R Do NOT set E03-01 to a value of 0 (V/f Control) when using E-Lift in hoist applications.
Page 128 D A N G E R If any undesired motions occur while E-Lift is active, immediately remove any RUN commands, turn off the E-Lift MFDI, and contact Magnetek. If steps 4.a through 4.e were successful, turn off the E-Lift MFDI and return the hoist to normal operations.
Page 129: Digital Input Option Set-Up (Di-A3 And S4Io)
Digital Input Option Set-up (DI-A3 and S4IO) Selects the digital input controls for either the DI-A3, S4I, or S4IO option when installed. Table 5-34: Digital Input Set-up Parameter Settings Parameter Display Function Range Default Digital In Sel Provides additional programmable 0–2, 5 C09-01 MFDI...
Page 130: Weight Measurement
Weight Measurement ® The IMPULSE •G+ & VG+ Series 4 includes a Weight Calculation function that can be used in hoisting applications. The weight measurement calculation is based on motor torque at a constant speed. The drive must pause the acceleration, wait for the torque to stabilize, and then perform the weight calculation based on the system tare values.
Page 131: System Tare And Calibration For Weight Measurement
PLC interface, the most accurate feedback can be obtained from the drive with the use of the drive’s RS-485 Memobus interface, similar to the architecture implemented with Magnetek’s RDSI systems. An analog interface can also be implemented, but it is important to understand the analog input and output resolution’s effect on feedback accuracy before implementation.
Page 132: Slack Cable Detection
Slack Cable Detection ® IMPULSE •VG+ Series 4 offers Slack Cable Detection for hoist applications. The Slack Cable condition is detected when the torque output is drastically reduced and has dipped below a set-point (C11-03) level. When Slack Cable condition occurs, the output action is defined by the C11-02 which has six selections.
Page 133 Parameter Display Function Range Default Model C11-03 SLC Detect Torq Percentage of Output Torque -50–100% below which the enabled Slack Cable Detection is activated-as long as the Frequency output is between C11-04 and C11-06, and the delay time is between C11-05 and C11-07.
Page 134: Snap Shaft Detection
Snap Shaft Detection This feature is designed to detect a broken or loose coupling by monitoring for a speed deviation between rotating shafts on a drive train. Ideally, mount one encoder on the motor, which drives the gearbox and one encoder on the last rotating part of the drive train, usually near the drum if used for a hoist motion.
Page 135: Brake Delay Timers
Brake Delay Timers This function is used in trolley or bridge applications. It can reduce the mechanical brake wear when the operator tries to position a load. This function is available only in traverse mode and the constant B03-03 must be set to 4 (Decel With Timer). Table 5-38: Delay Timers Parameter Settings Parameter Display...
Page 136: Maintenance Timer
Maintenance Timer The “Maintenance Timer” is a maintenance feature that will alert an operator, for example, when the bearings need to be greased. It consists of a Multi-Function Output (H02-0x–08 = 37) that becomes active when the total running time has exceeded the amount of time (in hours) programmed in parameter C12-05 and the frequency reference will be multiplied by a programmable gain (C12-06) to slow the motion down until the bearings have been greased.
Page 137: Inching Control
Inching Control Inching Control Function can be enabled by programming H01-01–08 = 17, 18, and 19, respectively. The frequency reference used during inching is determined by B01-17 (Jog Reference). C A U T I O N A directional input is not needed to enable motor torque. Table 5-42: Inching Control Parameter Settings Parameter Display...
Page 138: Index Function
Index Function Indexing allows for precise movement of the motor each time a run command is applied by the operator and the Index function is enabled by a Multi-Function Input (H01-xx = 60). This function can only be used with Traverse (A01-03 = 0) and No Load Brake (A01-03 = 2) motions in Flux Vector Control Method (A01-02 = 3) and with any Speed Reference setting for A01-04.
Page 139 When Applied in No-Load Brake (NLB) Hoist (A01-03 = 2) When the motion is No-Load Brake Hoist and the Index Brake Control C13-12 = 2, the action of the brake is controlled by the No-Load Brake sequence. The Index function can be enabled at any time during operation and the action of the brake is described below in C13-12.
Page 140 Parameter Display Function Range Default Model C13-12 Index Brake Ctrl Configures brake behavior when TRAV: 0–2 NLB: 2 indexing (traverse only). NLB: 0, 2 else: 0 Open on Index Brake will open on Index Cmd and remain open until Index Cmd is OFF.
Page 141: Tuning
Tuning • D1 DC Injection Braking • D2 Motor Slip Compensation • D3 Torque Compensation • D4 Automatic Speed Regulator (ASR) Tuning • D5 Torque Control • D8 Dwell Function • D9 S-Curve Acceleration/Deceleration • D10 Carrier Frequency • D11 Hunting Prevention DC Injection ®...
Page 142: Motor Slip Compensation
Motor Slip Compensation As the load becomes larger, the motor speed is reduced and the motor slip increases. The slip compensation function keeps the motor speed constant under varying load conditions. D02-01 sets the slip compensation gain. When the gain is “1.0”, the output frequency is increased by 1% of the E01-06 setting at rated current.
Page 143: Automatic Speed Regulator (Asr) Tuning
Increase the torque compensation time constant in 10 ms increments when the motor’s output current is unstable. Decrease this value when speed response is slow. Parameter Display Function Range Default Model D03-01 Torq Comp Gain Sets the gain for the automatic 0.00–2.50 1.0* torque (voltage) boost function and...
Page 144 Adjusting the ASR Parameters in FLV The drive is preset to use ASR settings D04-01/02 over the entire speed range in FLV. If required by the application, a second set of ASR parameters (D04-03/04) can be automatically activated depending on the motor speed or by using a digital input. Refer to the description in D04-01/D04-02 and D04-03/D04-04 on page 5-59.
Page 145 Table 5-47: ASR Tuning Parameter Settings Parameter Display Function Range Default Model D04-01 ASR P Gain 1 Sets the proportional gain of the 0.00–300.00 20.00 speed control loop (ASR). D04-02 ASR I Time 1 Sets the integral time of the speed 0.000–10.000 0.500 control loop (ASR).
Page 146 Flux Vector (FLV) Parameters D04-03 and D04-04 define the ASR proportional gain an integral time at zero speed. The settings in D04-01 and D04-02 are used at speeds above the setting in D04-07. D04-07 is set by default to 0.0 so D04-01 and D04-02 are used by default over the entire speed range. However, changing D04-07 creates two levels of ASR control settings, as shown in Figure 5-19 below.
Page 147: Torque Control
Torque Control Please consult factory for application assistance regarding torque control. Typically, torque control should not be applied on a hoist. This function is used to avoid excessive changes in torque, which may be caused by abnormal resonance when the torque reference changes rapidly. Table 5-48: Torque Control Parameter Settings Parameter Display...
Page 148: Speed/Torque Control Switching
Speed/Torque Control Switching Speed control or torque control is used in traverse applications and can be selected “on the fly” with the VG+ drive by using the multi-function input speed/torque control selection command (H01-xx = 34). Table 5-49:Speed/Torque Control Switch Parameters Parameter Terminal Number Number...
Page 149 1. When the speed/torque control selection contact is OFF, speed control is activated. • Speed reference during speed control depends on the frequency reference selection (B03-01) setting. To use terminal A1, A2, or A3 as the master frequency reference, set B03-01 to “1.” •...
Page 150 Dwell Function The Dwell Function is used to temporarily hold the output frequency at a set reference for a set time. Enable by setting H01-01 – 08 to 65. Table 5-50:Dwell Function Parameter Settings Access Parameter Display Function Range Default Level D08-01 Dwell Ref @ Start...
Page 151: S-Curve Acceleration/Deceleration
S-Curve Acceleration/Deceleration An S-Curve pattern is used to reduce shock and provide smooth transitions during machine acceleration and deceleration. S-Curve characteristic time is the time from the output frequency to the set accel/decel time. See S-Curve Characteristic timing diagrams below and on the following page.
Page 152: Carrier Frequency
The Carrier Frequency group provides the ability to modify the drive’s output carrier frequency and drive overload level. C A U T I O N Consult Magnetek for drive derating before modifying the D10 group parameters. Failure to do so may result in equipment damage. Table 5-52: Carrier Frequency Parameter Settings...
Page 153: Hunting Prevention
Hunting Prevention Occasionally, in an application, resonance between the internal control system and the mechanical system causes instability. This is called hunting, and may cause a crane to vibrate at a lower speed (up to 30 Hz) and/or with a light load. The hunting prevention function monitors the motor flux and uses a special control circuit to “smooth out”...
Page 154: Motor Parameters
Motor Parameters • E1 V/f Pattern 1 • E2 Motor Set-up • E3 Test Mode Voltage/Frequency Pattern WA R N I N G Drive input voltage (not motor voltage) must be set in E01-01 for the protective features of the drive to function properly.
Page 155 • Factory setting is 230 (230V units) or 460 (460V units). • When E01-11 = 0, then the value of E01-11 is not used. • When E01-12 = 0, then the value of E01-12 is not used. • When E01-13 = 0, then the value of E01-13 is not used. An OPE10 error will occur if the following conditions are not met: E01-05 ...
Page 156 Table 5-56:V/f Parameters Parameter Display Function Range Default E01-03 V/f Selection Motor V/f selection V/f: 0–9, A–F, FF OLV: F, FF 60 Hz, Level 0 (Default for A01-03 = 0 (Traverse), A01-03 = 4 (Braketronic)) 60 Hz, Level 1 60 Hz, Level 2 60 Hz, Level 3 60 Hz, Level 4 (Default for A01-03 = 1 (Std Hoist))
Page 157 Table 5-57: Voltage/Frequency (V/f) Pattern Options (230 V) E01-04 E01-05* E01-06 E01-07 E01-08* E01-09 E01-10* E01-11 E01-12* E01-13* E01-03 60.0 230.0 60.0 15.0 60.0 230.0 60.0 16.1 60.0 230.0 60.0 17.3 10.4 60.0 230.0 60.0 18.4 11.5 60.0 230.0 60.0 19.6 12.7 60.0...
Page 158 E01-04 E01-05* E01-06 E01-07 E01-08* E01-09 E01-10* E01-11 E01-12* E01-13* E01-03 75.0 400.0 50.0 34.1 22.1 90.0 460.0 60.0 39.2 25.4 US (V/f) F 60.0 460.0 60.0 39.1 25.3 & FF Euro (V/f) F 50.0 200.0 50.0 34.0 22.0 & FF US (OLV) F 60.0 460.0...
Page 159: Motor Set-Up
Motor Set-up E2 constants define motor parameters. Normally, the default settings for E2 constants are determined by kVA selection (O02-04). In flux vector control and open loop vector, the E2 constants will be set automatically during auto-tuning. At minimum, the motor rated current should be entered into E02-01.
Page 160: Test Mode Configuration
Test Mode Configuration Test Mode is a troubleshooting aid that is intended for troubleshooting Flux Vector control method problems in the field. This feature cannot be left on indefinitely, as it will generate a fault after being on for a total accumulated time of ten minutes. At this time, the fault must be reset or the power must be cycled.
Page 161: Option Card Parameters
Option Card Parameters • F1 Encoder (PG-X3) Option Set-up • F2 Analog Input (AI-A3) Option Set-up • F4 Analog Output (AO-A3) Option Set-up • F5 Digital Output (DO-A3 or S4IO) Option Set-up • F6 Communication Option Card Set-up • F7 Ethernet Option Card Set-up Encoder (PG) Option Set-up Table 5-62: Encoder (PG) Option Set-Up Parameter Settings Parameter...
Page 162 Parameter Display Function Range Default Model F01-12 PG2 Rotation Sel Changing this parameter has the 0, 1 same effect as swapping A+ and A- encoder wires. Fwd = C.C.W. Fwd = C.W. F01-13 PG2 #Gear Teeth1 Sets the gear ratio between the 0–1000 motor shaft and the encoder (PG).
Page 163 Parameter Display Function Range Default Model F01-26 PG Deviation Sel Stopping method at excessive Traverse: 0–7 speed deviation. NLB: 5 @Spd Agree- Stops by deceleration time 1 - Decel B05-02. @Spd Agree- Coast to stop. Coast @SpdAgree-F- Decelerates by fast-stop B05-08. Stop @Spd Agree-Alm DEV displayed, operation...
Page 164: Analog Input (Ai-A3) Option Set-Up
Analog Input (AI-A3) Option Set-up Sets CH1 to CH3 input functions when AI-A3 option is connected. When the 3CH individual input is used, parameter B03-01 is automatically set to “1” (frequency reference from control circuit terminal). The option/inverter reference selection, which is selected by a multi-function digital input (H01-xx= “1F”), is disabled when using the AI-A3 option.
Page 165: Analog Output (Ao-A3) Option Set-Up
Analog Output (AO-A3) Option Set-up Selects the analog output monitors for channel 1 and 2 if the AO-A3 optional card is connected. Table 5-65: Analog Output Option Set-Up Parameter Settings Parameter Display Function Range Default F04-01 AO Ch1 Select Analog output option Channel 1 1–630 selection F04-02...
Page 166: Digital Output (Do-A3) And S4Io Option Set-Up
Digital Output (DO-A3) and S4IO Option Set-up Selects the multi-function digital output settings for channels 1 through 8 of the DO-A3 and S4IO option cards. Table 5-67: Digital Output Set-Up Parameter Settings Terminal Designation Parameter Display Range Default DO-A3 S4IO F05-01* DO Ch1 Select M1-PC...
Page 167 Selects the multi-function output selections for the DO-A3 option. Table 5-68: DO-A3 Output Mode Selection for IMPULSE®•G+ and VG+ Series 4 Parameter Output F05-09 Terminals Output Contents Type setting TD5 – TD11 OverCurrent (SC, OC, GF) TD6 – TD11 OverVoltage (OV) TD7 –...
Page 168: Profibus-Dp Communication Option Card Set-Up
Profibus-DP Communication Option Card Set-up Settings for the Profibus-DP communication option card SI-P3. Table 5-69: Communication Option Card Parameter Settings Parameter Display Function Range Default F06-01 Comm Bus Flt Sel Stopping method at 0–4 communication error. Decel to Stop Coast to Stop Fast-Stop Use B3-03 Method Alarm Only...
Page 169 Parameter Display Function Range Default F06-31 PB Clear Select Determines the operation when a 0, 1 “Clear Mode” command is received on the Profibus-DP option Card Reset to Zero Resets drive operation with a Clear mode command. Hold Prev Value Maintains the previous operation state when Clear mode command is given.
Page 170: Ethernet Option Card Set-Up (Ethernet Ip & Modbus Tcp/Ip)
Parameter Display Function Range Default F06-55 DN BAUD RATE MEM Displays the baud rate of the 0–2 DeviceNet network. (Read Only - Monitor) 125 kbps 250 kbps 500 kbps F06-56 DN Speed Scale Sets the scaling factor for the -15–15 speed monitor in DeviceNet.
Page 171 Parameter Display Function Range Default F07-14 Duplex Select Sets how the communication 0–2 between host/client will be determined Half Duplex Auto Negotiate Full Duplex F07-15 Baud Rate Sets the communication speed for 10, 100 Mbps the option card. 10 10 Mbps 100 100 Mbps F07-16 CommLoss Tout...
Page 172: Terminal Parameters
Terminal Parameters • H1 Digital Inputs • H2 Digital Outputs • H3 Analog Inputs • H4 Analog Outputs • H5 Serial Communication Set-up • H6 Pulse Input/Output Digital Inputs ® The IMPULSE •G+ and VG+ Series 4 has eight multi-function digital inputs for the set-up of numerous functions.
Page 173 Display Function Upper Lmt 1 N.C. Upper Limit - Slow Down; Normally Closed. UL1 - blinking Upper Lmt 2 N.C. Upper Limit - Stop; Normally Closed. UL2 - blinking Lower Lmt 1 N.C. Lower Limit - Slow Down; Normally Closed. LL1 - blinking Lower Lmt 2 N.C.
Page 174 Display Function 43 Timer Function Function settings by C12-03, C12-04. It is set with timer function output H02-01–H02-03 = 12. 47 Ref Sample Hold Analog frequency reference Sample / Hold. 48 Flt Latch Reset When a function is latched, toggle this input ON and then OFF to clear the fault.
Page 175: F1 And F2 Keys Function Selection
F1 and F2 Keys Function Selection The F1 and F2 keys on the keypad have the ability of being programmed with specific functions to imitate digital inputs. The table below displays the various settings, which are valid for these buttons. •...
Page 176: Digital Outputs
Digital Outputs ® The IMPULSE •G+ and VG+ Series 4 has three built-in multi-function digital outputs for indicating various conditions. Drive digital output capabilities can be increased with the installation of an S4IO or DO-A3 option card. The following table lists the function selections for the multi-function digital outputs and indicates the control methods during which each function can be enabled.
Page 177 Display Function Anti-Shock ON ON/CLOSED: When Anti-Shock is enabled and a torque spike is detected. OFF/OPEN: When torque is stable and a spike is not detected. DB Overheat ON/CLOSED: When the drive displays an “RH” or “RR” fault OFF/OPEN: When the drive is not in an “RH” or “RR” fault condition Fault ON/CLOSED: When the drive is in a fault condition (excluding CPF00 and CPF01) OFF/OPEN: When the drive is not in a fault condition...
Page 178 Display Function 25 During Load Flt ON/CLOSED: When drive is in Load Float OFF/OPEN: When drive is not in Load Float 26 Run Cmd is ON/CLOSED: When either a Forward or Reverse command is active on H01-xx Input OFF/OPEN: When neither a Forward or Reverse command is active on H01-xx 27 Load Check Det ON/CLOSED: When the drive has detected a Load Check fault OFF/OPEN: Normal operation 28 Slack Cable Det ON/CLOSED: When the drive has detected a Slack Cable...
Page 179 Display Function 40 through FF ON/CLOSED: When specific fault condition are detected (see Fault Annunciation) Flt Annunciate OFF/OPEN: Normal operation 102 through 1FF** Parameter Settings 2 through FF with inverse output. * This output does not have an inverse output ** Contact will open when power is disconnected IMPULSE®•G+ &...
Page 180: Digital Outputs-Alarm/Fault Annunciate (H02-01-03=40)
Digital Outputs—Alarm/Fault Annunciate (H02-01–03=40) Digital Outputs—Fault Annunciate enables you to assign a set of six fault outputs to Relay Output M2/M3 and/or Output M5/M6. In addition, you can select whether each fault output is enabled. NOTE: Output M0/M1 can also be used for Digital Outputs—Fault Annunciate; however, it is normally assigned to a brake output.
Page 181 Table 5-77: Fault Annunciate Example First digit from the left Second digit from the left 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 1 or 0 Set 2 Binary Number First digit from the left = 8...
Page 182 Table 5-79: Binary to Hexadecimal Conversion Hexadecimal Hexadecimal Binary Number Binary Number Number Number 0000 1000 0001 1001 0010 1010 0011 1011 0100 1100 0101 1101 0110 1110 0111 1111 External Fault Response Selection It is sometimes desirable to have at least one external fault input to the drive. To properly program a multi-function input (H01-01 to H01-08) for this purpose an external fault response must be selected.
Page 183: Analog Inputs
Analog Inputs ® The IMPULSE •G+ and VG+ Series 4 has three built-in analog inputs for the external input of numerous references and limits. Drive analog input capabilities can be increased with the installation of an AI-A3 option card. Table 5-81: Analog Inputs Parameter Settings Parameter Display Function...
Page 184 Parameter Display Function Range Default H03-14 A1/A2/A3 Sel Determines which analog input 1–7 terminals will be enabled when a digital input programmed for “MFAI Enable” (H01-xx = 3A) is activated. A1 Available A2 Available A1/A2 Available A3 Available A1/A3 Available A2/A3 Available All Available H03-15...
Page 185 Table 5-83: Option Selections for H03-02, H03-06, and H03-10 (V/f) Display Function Analog Freq Ref1 100% = Max output frequency (E01-04) Same value can be set using H03-02 and H03-10. 10V = E01-04 (Maximum output frequency) Frequency Gain The value of the analog frequency bias will be multiplied with the analog frequency reference gain value.
Page 186: Analog Outputs
Analog Outputs ® The IMPULSE •G+ and VG+ Series 4 has two built-in analog outputs for the external monitoring of drive conditions. Drive analog output capabilities can be increased with the installation of an AO-A3 option. Table 5-84: Analog Outputs Parameter Settings Parameter Display Function...
Page 187 Parameter Display Function Range Default 618 PG1 CounterValue 619 PG2 CounterValue 622 Zero Servo Pulse 625 ASR Out w/o Fil 626 FF Cont Output 627 FF Estimate SPD H04-02 Terminal FM Gain Gain multiplier for Terminal FM -999.9–999.9% 100.0 analog output signal H04-03 Terminal FM Bias Bias multiplier for Terminal FM...
Page 188: Serial Communication Set-Up
Serial Communication Set-up ® The IMPULSE •G+ and VG+ Series 4 uses terminals R to communicate the MODBUS RTU (RS-485/422) protocol. Cycle power after changing serial format parameters. Table 5-85: Serial Communication Set-up Parameter Settings Parameter Display Function Range Default H05-01 Serial Comm Adr Serial communication address...
Page 189 Parameter Display Function Range Default H05-11 Enter CommandSel 0, 1 Enter Required Drive requires an Enter command before accepting any changes to parameter settings. No EnterRequired Parameter changes are activated immediately without the Enter command. H05-12 Run CommandSel 0, 1 FWD Run &REV Run &...
Page 190: Pulse Train Input/Output
Pulse Train Input/Output Pulse Input and Output provides speed control capabilities via the RP and MP terminals. Table 5-86: Pulse Input/Output Parameter Settings Parameter Display Function Range Default H06-01 Pulse Input Sel Selects the function of pulse input 0, 5–7 terminal RP.
Page 191: Protection Parameters
Protection Parameters • L1 Motor Overload • L2 Power Loss Ride Thru • L3 Stall Prevention • L4 Reference Detection • L5 Test Mode • L6 Torque Detection • L8 Hardware Protection • L9 Automatic Fault Reset • L9 Fault Latch Motor Overload ®...
Page 192: Power Loss Ride Thru
Parameter Display Function Range Default L01-03 Mtr OH Alarm Sel Operation when the motor 0–3 temperature analog input (H03-02, H03-06, or H03-10 = E) exceeds the OH3 alarm level. (1.17V) Decel to Stop Coast to Stop Fast Stop (Alarm) Decel by B05-08 Alarm Only OH3 Flashes L01-04...
Page 193: Stall Prevention
Stall Prevention Table 5-89: Stall Prevention Parameter Settings Parameter Display Function Range Default Model L03-01 StallP Accel Sel Sets how the Stall Prevention will 0–2 function during acceleration. Disabled General Purpose Acceleration is paused as long as the current is above the L03-02 setting.
Page 194 Parameter Display Function Range Default Model L03-21 Acc/Dec P Gain Sets the proportional gain used to 0.10–10.00 A01-02 G+/VG+ calculate the deceleration rate during KEB Ride-Thru, OV suppression function, and Stall Prevention during deceleration. L03-23 CHP Stall P Sel This function reduces the Stall 0, 1 Prevention during run level in the constant power range.
Page 195: Speed Agree
Speed Agree ® The IMPULSE •G+ and VG+ Series 4 utilizes three different functions for detecting output frequency: Speed Agree 1 • When enabled using MFDO "H02-xx = 2", the contact closes when the output frequency (U01- 02) is equal to the frequency reference (U01-01) plus or minus the speed agree detection width (L04-02).
Page 196 Table 5-90: Speed Agree Parameters Parameter Display Function Range Default L04-01 Spd Agree Level Sets the detection level for the 0.0–150.0 Hz desired speed agree 1 and frequency detection functions. The detection level is effective during both FWD and REV operation. L04-02 Spd Agree Width Sets the detection width for speed...
Page 197: Test Mode
Test Mode Test Mode is a troubleshooting aid that is intended for troubleshooting Flux Vector Control Method problems in the field. The feature cannot be left on indefinitely as it will generate a fault after being on for a total accumulated time of 10 minutes. At this time, the fault must be reset or power must be cycled.
Page 198: Torque Detection
Torque Detection The overtorque detection circuit activates when the motor load causes the motor current to exceed the overtorque detection level (L06-02). When an overtorque condition is detected, alarm signals can be sent to a multi-function output. To output an overtorque detection signal, select torque detection 1 at either of the multi-function digital outputs (H02-0x = “B”...
Page 199 Table 5-95: Torque Detection Parameter Settings - continued Parameter Display Function Range Default L06-02 Torq Det 1 Lvl Sets the overtorque detection as a 0–300% percentage of inverter rated current, during V/f control, and motor rated torque during vector control. L06-03 Torq Det 1 Time The overtorque detection delay time...
Page 200 Table 5-97: Torque Detection Parameter Settings - continued Parameter Display Function Range Default L06-05 Torq Det 2 Lvl Torque Detection 2 Level 0–300% L06-06 Torq Det 2 Time Torque Detection 2 Time 0.0–10.0 sec L06-08 Mech Fatigue Sel This function can detect an 0–8 overtorque or undertorque in a certain speed range as a result of...
Page 201: Hardware Protection
Hardware Protection ® The IMPULSE •G+ and VG+ Series 4 comes equipped with a number of built-in functions designed to protect the inverter and its components from damage. Table 5-100: Hardware Protection Parameter Settings Parameter Display Function Range Default L08-02 OH Pre-Alarm Lvl Sets the heatsink temperature level for 50–150°C...
Page 202 Parameter Display Function Range Default L08-18 Soft CLA Sel Enables/disables the software current 0, 1 limit function. Disabled Enabled L08-19 Fc Red dur OHAlm Specifies the frequency reference 0.1–0.9 Hz reduction gain at overheat pre-alarm when L08-03 = 4. L08-32 MC,FAN Fault Sel MC, FAN configure the operation of 0–4...
Page 203 Parameter Display Function Range Default L08-55 DB Tr protection Internal Braking Transistor Protection 0, 1 (DB Tr protection) Disabled Disable braking transistor protection when not using the internal braking transistor. Enabled Enable when connecting a braking resistor or a braking resistor unit to the drive's built-in braking transistor.
Page 204: Automatic Fault Reset
Automatic Fault Reset ® When a fault occurs during operation, the IMPULSE •G+ and VG+ Series 4 can be programmed for an auto reset operation to automatically reset the fault. Table 5-101: Automatic Reset Parameter Settings Parameter Display Function Range Default L09-01 Reset Select...
Page 205 Example: Enable auto-reset for UV1 and CE faults. Table 5-102: Auto-Reset Programming Digit 4 Digit 3 Digit 2 Digit 1 Binary L09-04 Binary L09-05 Table 5-103: Auto-Reset Programming Summary L09-04 Binary L09-05 Binary Digit 4 0000 Digit 4 0000 Digit 3 0000 Digit 3 0000...
Page 206: Fault Latch Selection
Fault Latch Selection The Fault Latch function allows for specific faults to become “latched” after the automatic fault reset attempts (L09-02) has maxed out. The Reset key on the keypad will be blocked from clearing the fault, and the fault can only be cleared by any of the methods explained below. In the case of a power loss, the fault will remain latched when power is restored.
Page 207: Operator Parameters
Operator Parameters • O1 Monitor Selection • O2 Keypad Key Selection • O3 Clear History • O4 Copy Function Monitor Selection The top level in the operation mode allows the viewing of four monitor variables. They are Fref, Fout, Iout, and User-Selected monitor. This user-selected monitor can be selected from the following table.
Page 208 Parameter Display Function Range Default 160 PG CH1 Count 161 PG CH2 Count 321 RUN Cmd Counter 401 Drv Elapsed Time 403 Fan Elapsed Time 404 Fan Life Mon 405 Cap Life Mon 406 ChgCirc Life Mon 407 IGBT Life Mon 408 Heatsink Temp 410 kWh Lower 4 dig 411 kWh Upper 5 dig...
Page 209 Parameter Display Function Range Default O01-02 Power-On Monitor Selects the monitor to be 1–5 displayed on the digital operator immediately after the power supply is turned on. Frequency Ref Frequency reference (U01-01) FWD/REV Forward/Reverse Output Freq Output frequency (U01-02) Output Current Output current (U01-03) User Monitor User-selected monitor (set by...
Page 210: Keypad Key Selection
Display Function Range Default O02-01 LO/RE Key Pressing the LO/RE Key once 0, 1 displays: “Call Magnetek at 1-866- 624-7378”. Mode/Service Control Method (A01-02) Pressing the LO/RE Key a second time: Motion (A01-03) Speed Reference (A01-04) Pressing the LO/RE Key a third...
Page 211 Parameter Display Function Range Default 73 2_0169 2145-G+/VG+S4 74 2_0211 2180-G+/VG+S4 75 2_0250 2215-G+/VG+S4 76 2_0312 2283-G+/VG+S4 77 2_0360 2346-G+/VG+S4 78 2_0415 2415-G+/VG+S4 92 4_0002 4001-G+/VG+S4 93 4_0004 4003-G+/VG+S4 94 4_0005 4004-G+/VG+S4 95 4_0007 4005-G+/VG+S4 96 4_0009 4007-G+/VG+S4 97 4_0011 4009-G+/VG+S4 99 4_0018 4014-G+/VG+S4...
Page 212 Parameter Display Function Range Default D5 5_0125 5099-G+/VG+S4 D6 5_0145 5130-G+/VG+S4 D7 5_0192 5172-G+/VG+S4 D9 5_0242 5200-G+/VG+S4 O02-05 Operator M.O.P. Selects whether the ENTER key is 0, 1 used when the frequency reference is set by the digital operator. The digital operator can simulate a motor operated potentiometer (M.O.P.) by setting this parameter.
Page 213: Maintenance History
Maintenance History Table 5-109: Clear History Parameter Settings Parameter Display Function Range Default O03-01 Elapsed Time Set Sets the value for the cumulative 0–9999 x 10 hr operation time of the drive in units of 10 hours. Cumulative time can be viewed using monitor Cumulative Operation Time (U04-01).
Page 214: Copy Function
Copy Function Table 5-110: Copy Function Parameter Settings Parameter Display Function Range Default O04-01 Copy Function Sel Copy parameters to/from keypad 0–3 COPY SELECT   OP READ Drive Keypad   INV WRITE Keypad Drive OP ↔ INV VERIFY Keypad ↔ Drive O04-02 Read Allowable Enables/disables copy function...
Page 215 An error may occur while saving the parameter values to the digital operator’s memory. If an error is displayed, press any key to cancel the error display and return to parameter O04-01. Error displays and their meanings are covered in Chapter 6: Troubleshooting of Copy function Related Faults. To COPY the parameter values into a Drive, set O04-01 = 2 (OP ...
Page 216 If all the parameters stored in the digital operator do not match those programmed in the Drive, the digital operator displays the following: VERIFY ERROR The digital operator will not display which parameters did not match, only that the verification found discrepancies in some parameter values.
Page 217: Monitor Parameters
Monitor Parameters • U1 Monitor • U2 Fault Trace • U3 Fault History • U4 Maintenance • U6 Control Monitor Table 5-111: Monitor Parameters Parameter Display Function Units U01-01 Frequency Ref Frequency Reference U01-02 Output Freq Inverter Output Frequency U01-03 Output Current Inverter Output Current U01-04...
Page 218 Parameter Display Function Units U01-12 Int Ctl Sts 1 Operation Status U01-14 CPU 1 SW Number Flash ROM software ID number U01-15 Term A1 Level External Terminal Input level U01-16 Term A2 Level External Terminal Input level U01-17 Term A3 Level External Terminal Input level U01-20 SFS Output...
Page 219 Parameter Display Function Units U01-52 MaintenanceTimer Hours since last timer reset. U01-53 Index Count Number of motor revolutions the shaft has moved since the Revs beginning of a new Index command. U01-54 Term RP Inp Freq Displays the frequency of pulse train input terminal RP. U01-60 PG CH1 Count Displays the raw PG Channel 1 pulse count...
Page 220 Parameter Display Function Units SFS Output Displays the speed reference for the soft starter at the U02-15 previous fault (U02-02). Motor Iq Current Displays the q-axis current for the motor at the previous fault U02-16 (U02-02). Motor Id Current Displays the d-axis current for the motor at the previous fault U02-17 (U02-02).
Page 221 Table 5-114: Maintenance Parameters Parameter Display Function Units U04-01 Drv Elapsed Time Displays the cumulative operation time of the drive. The value for the cumulative operation time counter can be reset in parameter O03-01. Use parameter O03-02 to determine if the operation time should start as soon as the power is switched on or only while the Run command is present.
Page 222 Parameter Display Function Units U04-38* FAN Alarm Axis Displays the module where the FAn alarm occurred as a binary number. U04-39* VOF Alarm Axis Displays the module where the voF alarm occurred as a binary number. * Available only for 4810 and 41090 models. Table 5-115: Control Monitor Parameters Parameter Display...
Page 223: Chapter 6: Troubleshooting
C h a p t e r Troubleshooting...
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Page 225: Troubleshooting The Drive
Troubleshooting the Drive In this troubleshooting section, “Check,” means investigating whether an item is functioning and in an acceptable physical condition, and then taking corrective action (adjusting, fixing, replacing, etc.) as necessary. In the “Corrective Action” column, you may not have to perform all of the steps to correct the problem.
Page 226 Symptom Corrective Action Motor rotates, but at minimum speed only. 1. Check wiring of speed inputs. 2. Verify speed reference setting (A01-04). 3. Verify reference and run source settings are correct (B03- 01, -02). 4. Verify reference priority setting (B01-18). 5.
Page 227 Code Fault/Alarm Description Corrective Action Torque Proving Fault. Before the 1. Ensure the motor has been Auto- brake is released, the drives current/ tuned successfully. No Current torque did not reach Initial Brake 2. Confirm that the holding brake is Release Torque level (C08-16) within closed.
Page 228 CPF01 2. If the problem continues, replace circuit, or the connector on the the control board or the entire operator is damaged. drive. Contact Magnetek for instructions on replacing the control board. 3. Replace the operator if it is damaged.
Page 229 2. If the problem continues, replace noise interference. the control board or the entire drive. Contact Magnetek for instructions on replacing the control board. Noise Interference: 1. Check the various options available to minimize the effects of noise.
Page 230 The hardware is board and the drive. damaged. 2. If the problem continues, replace the control board or the entire drive. Contact Magnetek for instructions on replacing the control board. CPF24 Drive Unit Signal Fault. The drive 1.
Page 231 Code Fault/Alarm Description Corrective Action External fault occurs on Terminal S4. 1. Check constant H01-04 for proper programming. Alarm or fault defined by the External External Fault Selection table (table 5-80 on 2. Check the condition of the input Fault 4 page 5-96).
Page 232 Code Fault/Alarm Description Corrective Action LC Done Load Check Done Alarm. This 1. None. alarm is displayed after the LC set up process is done. The alarm will clear Load Check Done when the Down command is pressed and complete the LC set up process. An open phase occurred at the 1.
Page 233 Code Fault/Alarm Description Corrective Action Motor Overheating 1. Thermistor 1. Check the motor rated current analog input detected motor value, E02-01. Motor Overheat 1 overheating. See L01-03. Alarm 2. Increase cycle time or reduce the defined by L01-03. load. Motor Overheating 2. Thermistor analog input detected motor Motor Overheat 2 overheating.
Page 234 Code Fault/Alarm Description Corrective Action PULSDEV Pulse Deviation. The pulse input 1. During operation, verify that there into terminal RP compared to the is an incoming pulse signal on Pulse Deviation pulse output from terminal MP is the RP terminal, viewable at U01- greater than the percentage programmed into H06-09.
Page 235 Exclusive to 4810 and 41090 models. entire drive. For instructions on replacing the gate drive board, contact Magnetek or a Magnetek representative. Output Voltage Detection Fault. 1. Replace the drive. Problem detected with the voltage on the output side of the drive.
Page 236 Code Error Name/Description Corrective Action OPE02 Setting Out of Range. Parameter 1. With the fault displayed on the setting is out of range. keypad, press the ENTER key to Limit reveal the “Out of Range” parameter via the U01-34 monitor. 2.
Page 237 Code Error Name/Description Corrective Action OPE19 Incompatible Setting of Stopping 1. Satisfy B03-03 > 6 and A01-02 < 1. Method and Control Method. Stp-Mthd & Ctrl OPE20 Electronic Programmable Limit 1. Check if C03-14 = 0, 2 or 4: Switch Setting Error. C03-19 >...
Page 238: Troubleshooting Encoder Related Faults
Troubleshooting Encoder Related Faults The faults in this section may involve the encoder feedback system. During system startup, these faults are often caused by parameters that need to be adjusted. However, after the system has been running for some time without a fault, this usually indicates a problem with the physical system and adjusting the parameters should only be done after the physical system has been inspected.
Page 239: Fault Code: Pgo-X-S/Pgo-X-H-Pulse Generator Signal Fault
7. If the encoder feedback system checks out and no other mechanical problems can be found, then something must have changed in the control system. 7.1 Check if the acceleration or deceleration times have been changed (B05-01, B05-02, C01- 02, C01-04, or C01-05). 7.2 Check if a function that provides an alternate acceleration or deceleration rate has been enabled or changed (Quick Stop, Reverse Plug Simulation, Accel/Decel Time 2).
Page 240: Fault Code: Be1-Rollback Fault
6. After corrective action has been taken and the fault no longer occurs then the load float time, C08-10, can be set back to initial value. Fault Code: BE1–Rollback Fault Definition The BE1 fault indicates that the drive has released the brake, but has not started to accelerate the motor when it detects more than the expected encoder feedback.
Page 241: Fault Code: Be3-Brake Release Fault
coupling (depending on the type of encoder used). If the pulse wheel is misaligned or the shaft coupling is loose the drive may get erratic pulse signals possibly causing a BE2 fault. Repairs to the encoder wheel or shaft coupling should be made immediately before again attempting to operate the hoist.
Page 242: Alarm Code: Be6-Brake Proving Alarm
Alarm Code: BE6–Brake Proving Alarm Definition The BE6 alarm indicates that the drive has commanded the brake to set but it has detected more encoder pulse feedback than expected. A BE6 alarm will occur if the number of pulses received during the BE6 detection time (C08-12) is greater than the expected number of pulses (C08-13).
Page 243 Corrective Action 1. Check the brake for proper operation and adjustment. If the brake does not set, is improperly adjusted or is excessively worn, it may not be able to hold the load. This will allow the encoder pulses received while the brake is set. 2.
Page 244: Fault Code: Oc-Over Current Fault
Fault Code: OC–Over Current Fault Definition An over current fault is caused if the output current exceeds 200% of the inverter rated output current. This fault can be caused by short circuits in the wiring or in the motor, and it can also be caused by parameters that are not adjusted properly.
Page 245: Fault Display And Corrective Actions At Auto-Tuning
Fault Display and Corrective Actions at Auto-Tuning The following are fault displays and corrective actions at auto-tuning. If any of the following faults are found, the digital operator displays that fault contents; the motor coasts to stop if it is under operation.
Page 246 Fault Display Fault or Indicator Name/Description Corrective Action End 1* Excess V/f setting (Rotation type tuning • Check the T1 parameters. only). The torque reference exceeded 100% • Disconnect the motor from the load. and no load current exceeded 70%. V/f Oversetting End 2 Motor Iron Core Saturation Coefficient...
Page 247: Troubleshooting Option Card Related Faults
Troubleshooting Option Card Related Faults Drive-Side Error Codes Table 6-6 lists the various fault codes related to option cards. Check the following items first when an error code occurs on the drive: • Communication cable connections. • Make sure the option is properly installed to the drive. •...
Page 248 CN5- supports the option AO-A3 A is incompatible with card to be installed. DI-A3 the drive. Contact Magnetek for assistance. DO-A3 • A PG option card is connected to option • PG option cards are port CN5-A.
Page 249 AO-A3 • If the problem DI-A3 continues, replace the oFC11 DO-A3 control board or the entire drive. Contact Magnetek for S4IO instructions on replacing the control board. oFC12 A1-A3 Option Card Fault at • Option card or • Cycle power to the Option Port CN5-C.
Page 250: Copy Function Related Faults
Fault or Indicator Error Card Name/Description Cause Possible Solution oPE07 A1-A3 Multi-function Analog • At least two analog • Adjust H03-02, Input Selection Error. input terminals are set H03-06, and H03-10 to the same function. settings so functions no longer conflict. •...
Page 251 Fault Display Fault or Indicator Name/Description Corrective Action ndAT Model, Voltage Class, Capacity Mismatch. • Make sure model numbers and specifications are the same for both drives. • The drive from which the parameters were copied and the drive to which the •...
Page 252: Power Section Check
Power Section Check WA R N I N G Do NOT touch any circuit components while AC main power is on or immediately after the main AC power is disconnected from the unit. You must wait until the red “CHARGE” lamp is extinguished.
Page 253: S4If Replacement Procedure
S4IF Replacement Procedure WA R N I N G Do NOT touch any circuit components while AC main power is on or immediately after the main AC power is disconnected from the unit. You must wait until the red “CHARGE” lamp is extinguished.
Page 254 8. Loosen the two retaining screws (A) pictured in Figure 6-2. 9. Remove existing interface card by grasping each corner at TB6 and TB5 and slide down until free. 10. Return I/O board to ESD bag 11. Complete all main circuit terminal connections as the installation of the S4IF interface card may block wiring access.
Page 255 a p p e n d i x ® IMPULSE •G+ & VG+ Series 4 Parameter Listing...
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Page 257 ® IMPULSE •G+ & VG+ Series 4 Parameter Listing Parameter Parameter Name Default Range Units Reference A01-01 Access Level 0–2 A01-02 Control Method 0, 2, 3 A01-03 Motion G+: 1 0–2, 4 4-10 VG+: 2 A01-04 Speed Reference 0–8 4-10 A01-05 Init Parameters 0–8880...
Page 258 Parameter Parameter Name Default Range Units Reference B03-07 LO/RE RUN Sel 0, 1 5-10 B03-08 RUN CMD at PRG 0, 1 5-10 B03-10 AllowRun@PowerUp 0, 1 5-10 B03-15 Ref Source 2 0–4 5-10 B03-16 Run Source 2 0–3 5-11 B03-21 PG Start Sel 0, 1 5-11...
Page 259 Parameter Parameter Name Default Range Units Reference C03-07 Lmt Stop Method 0–2 5-19 C03-08 UL3 Stop Method 0–5 5-19 C03-09 UL3 Decel Time 0.0–25.5 5-19 C03-10 Phantom Stop Met 0–2 5-20 C03-11 Load Share Limit 0, 1 5-20 C03-12 Klixon Action 0, 1 5-21 C03-13...
Page 260 Parameter Parameter Name Default Range Units Reference C05-28 Dly Trig Freq 30.0 0.0–60.0 5-29 C06-01 Swift-Lift (V/f and OLV) 0–4 5-30 Ultra-Lift (FLV) C06-02 SwiftLift FWDSpd (V/f and OLV) 60.0 0.1–150.0 5-30 UltraLift FWDSpd (FLV) C06-03 SwiftLift REVSpd (V/f and OLV) 60.0 0.1–150.0 5-30...
Page 261 Parameter Parameter Name Default Range Units Reference C07-18 Smoothing Time 1.00 0.00–2.55 5-36 C07-20 Steadying Time 0.20 0.00–0.50 5-36 C07-22 AlarmDisplayTime 0–30 5-36 C07-23 No Load Torque 0–100 5-36 C07-24 Required Torque 0–180 5-36 C07-25 Detection Method 0–2 5-36 C08-01 Torque Comp Time 1.00 0.00–2.55...
Page 262 Parameter Parameter Name Default Range Units Reference C09-09 DIO Terminal 8 0–FF 5-43 C09-10 DIO Terminal 9 0–FF 5-43 C09-11 DIO Terminal 10 0–FF 5-43 C09-12 DIO Terminal 11 0–FF 5-43 C09-13 DIO Terminal 12 0–FF 5-43 C09-14 DIO Terminal 13 0–FF 5-43 C09-15...
Page 263 Parameter Parameter Name Default Range Units Reference C13-04 Index Revs 0–65535 5-53 C13-05 Index Count 0–65535 pulses 5-53 C13-06 Index Rpt Delay 0.00 0.00–60.00 5-53 C13-07 Index Complete 0–32767 pulses 5-53 C13-08 Index Zsv Gain 0–100 5-53 C13-09 Index ASR P Gain 30.00 0.00–300.00 5-53...
Page 264 Parameter Parameter Name Default Range Units Reference D04-37 NLB Strt ASR Dly 0.50 0.00–2.55 5-59 D05-01 Torq Control Sel 0, 1 5-61 D05-02 Torque Ref Filter 0–1000 5-61 D05-03 Speed Limit Sel 1, 2 5-61 D05-04 Speed Lmt Value -120–120 5-61 D05-05 Speed Lmt Bias...
Page 265 Parameter Parameter Name Default Range Units Reference E01-08 Mid Voltage A Determined 230V: 0.0– 5-70 by E1-03 255.0 460V: 0.0– 510.0 575V: 0.0– 733.1 E01-09 Min Frequency Determined 0.0–150.0 5-70 by E1-03 E01-10 Min Voltage Determined 230V: 0.0– 5-70 by E1-03 255.0 460V: 0.0–...
Page 266 Parameter Parameter Name Default Range Units Reference E03-09 Min Voltage Determined 230V: 0.0– 5-74 by E01-03 255.0 460V: 0.0– 510.0 575V: 0.0– 733.1 E03-10 Mid Frequency B 0.0–150.0 5-74 E03-11 Mid Voltage B 230V: 0.0– 5-74 255.0 460V: 0.0– 510.0 575V: 0.0–...
Page 267 Parameter Parameter Name Default Range Units Reference F02-03 AI Input Bias -999.9– 5-78 999.9 F04-01 AO Ch1 Select 1–630 5-79 F04-02 AO Ch1 Gain 100.0 -999.9– 5-79 999.9 F04-03 AO Ch2 Select 1–630 5-79 F04-04 AO Ch2 Gain 50.0 -999.9– 5-79 999.9 F04-05...
Page 268 Parameter Parameter Name Default Range Units Reference F06-58 DN Torque Scale -15–15 5-84 F06-59 DN Power Scale -15–15 5-84 F06-60 DN Voltage Scale -15–15 5-84 F06-61 DN Time Scale -15–15 5-84 F06-62 DN Heart Beat 0–10 5-84 F06-63 DN MAC ID MEM 0–63 5-84 F07-01...
Page 269 Parameter Parameter Name Default Range Units Reference H01-09 F1 Key Selection 0F–74 5-89 H01-10 F2 Key Selection 0F–74 5-89 H01-14 Alt Ref Override 0, 1 5-86 H02-01 Term M0-M1 Sel 0–1FF 5-90 H02-02 Term M2-M3 Sel 0–1FF 5-90 H02-03 Term M5-M6 Sel 0–1FF 5-90 H02-06...
Page 270 Parameter Parameter Name Default Range Units Reference H05-04 Serial Fault Sel 0–3 5-102 H05-05 Serial Flt Dtct 0, 1 5-102 H05-06 Transmit WaitTIM 5–65 5-102 H05-07 RTS Control Sel 0, 1 5-102 H05-09 CE Detect Time 0.0–10.0 5-102 H05-10 CommReg 25h Unit 0, 1 5-102 H05-11...
Page 271 Parameter Parameter Name Default Range Units Reference L03-17 DC Bus Reg Level 230 V: 375 230 V: 150– 5-107 460 V: 750 460 V: 300– 575 V: 930 575 V: 431– 1150 L03-20 DC Bus P Gain A01-02 0.00–5.00 5-107 L03-21 Acc/Dec P Gain A01-02...
Page 272 Parameter Parameter Name Default Range Units Reference L08-35 Installation Sel 0–3 5-116 L08-38 Fc Reduct dur OL 0–2 5-116 L08-40 FC Reduct Time A01-02 0.00–2.00 5-116 L08-41 High Cur Alm Sel 0, 1 5-116 L08-55 DB Tr protection 0, 1 5-117 L09-01 Reset Select...
Page 273 Parameter Parameter Name Default Range Units Reference T01-01 Tuning Mode Sel 0–2 4-17 T01-02 Rated Horsepower 4-17 T01-03 Rated Voltage 4-17 T01-04 Rated Current 4-17 T01-05 Rated Frequency 60.0 4-17 T01-06 Number of Poles Poles 4-17 T01-07 Rated Speed 1750 4-17 T01-08 PG Pulses/Rev...
Page 274 Parameter Parameter Name Default Range Units Reference U01-52 MaintenanceTimer 5-133 U01-53 Index Count Revs 5-133 U01-54 Term RP Inp Freq 5-133 U01-60 PG CH1 Count Pulse 5-133 U01-61 PG CH2 Count Pulse 5-133 U01-63 PG CH1 Freq 5-133 U01-64 PG CH2 Freq 5-133 U01-65 PG Output Freq...
Page 275 Parameter Parameter Name Default Range Units Reference U03-08 Fault Message 8 5-134 U03-09 Fault Message 9 5-134 U03-10 Fault Message 10 5-134 U03-11 Elapsed Time 1 5-134 U03-12 Elapsed Time 2 5-134 U03-13 Elapsed Time 3 5-134 U03-14 Elapsed Time 4 5-134 U03-15 Elapsed Time 5...
Page 276 Parameter Parameter Name Default Range Units Reference U06-01 Mot SEC Current 5-136 U06-02 Mot EXC Current 5-136 U06-03 ASR Input 5-136 U06-04 ASR Output 5-136 U06-05 Voltage Ref (Vq) 5-136 U06-06 Voltage Ref (Vd) 5-136 U06-07 ACR(q) Output 5-136 U06-08 ACR(d) Output 5-136 U06-18...

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Magnetek Impulse G+ series 4 Instruction Manual

Chapter 1: Introduction

Chapter 2: Installation

Chapter 3: Wiring

Chapter 4: Getting Started

Chapter 5: Programming Advanced Features

Chapter 6: Troubleshooting

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