Magnetek Impulse-t 2006-T Instruction Manual
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Magnetek Impulse-t 2006-T Instruction Manual

Magnetek Impulse-t 2006-T Instruction Manual

Adjustable frequency crane controls
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Adjustable Frequency Crane Controls
Instruction Manual
Software #5073 October 2015
Part Number: 144-26158 R3
© Copyright 2015 Magnetek

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Summary of Contents for Magnetek Impulse-t 2006-T

  • Page 1 Adjustable Frequency Crane Controls Instruction Manual Software #5073 October 2015 Part Number: 144-26158 R3 © Copyright 2015 Magnetek...
  • Page 3 Instructions, manuals, and safety warnings of the manufacturers of the equipment where the Magnetek Products are used, • Plant safety rules and procedures of the employers and the owners of the facilities where the Magnetek Products are being used, •...

  • Page 4: Danger, Warning, Caution, And Note Statements

    DANGER, WARNING, CAUTION, and NOTE Statements DANGER, WARNING, CAUTION, and NOTE statements are used throughout this manual to emphasize important and critical information. You must read these statements to help ensure safety and to prevent product damage. The statements are defined below. D A N G E R DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

  • Page 5: Table Of Contents

    Contents: PREFACE AND SAFETY ..........i DANGER, WARNING, CAUTION, and NOTE Statements .
  • Page 6 S-Curve Acceleration/Deceleration ........5-9 Motor Parameters.

  • Page 7: Introduction

    C h a p t e r Introduction...
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  • Page 9 WA R N I N G Read and understand this manual before installing, operating, or servicing this drive. All warnings, cautions, and instructions must be followed. All activity must be performed by qualified personnel. The drive must be installed according to this manual and local codes. Do not touch any circuitry components while the main AC power is on.
  • Page 10 Introduction The IMPULSE•T drive is the next generation of Magnetek, Inc. drives, providing compact and economical crane control. The drive maintains a similar footprint size to previous generation drives. The drive includes: • Volts/Hertz Control • Up to 8 Discrete Speed References •...

  • Page 11: Impulse•T General Specifications

    IMPULSE•T General Specifications 230V Class - Standard Specification Specification Values and Information for Each 230V-Class Model 2006-T 2010-T 2012-T Rated output current (A) 12.0 Capacity (kVA) 460V Class - Standard Specification Specification Values and Information for Each 460V-Class Model 4002-T 4004-T 4005-T 4009-T...
  • Page 12 Specification Specification Value and Information for All Models Storage temperature -4° to 140°F (-20° to 60°C) Humidity 95% relative; noncondensing Vibration 1 G less than 20 Hz; 0.2 G for 20–55 Hz Elevation 3300 Ft. (1000 m) or less AC Reactor Specifications Reactors, both as input (line) and output (load) devices, protect adjustable frequency drives, motors, and other load devices against excessive voltage and current.
  • Page 13 IMPULSE•T External Resistor Specifications Table 1-3: External Resistor Specifications Traverse IMPULSE•T Resistor Part No. Resistor Part No. Model Number - CMAA Class C CMAA Class D Finned 2006-T EDB2003CT EDB2004DTP* 2010-T EDB2006CT EDB2006DTP* 2012-T EDB2009CT EDB2011DTP* 4002-T EDB4001CT EDB4002DTP* 4004-T EDB4003CT EDB4004DTP* 4005-T...
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  • Page 15: Chapter 2: Installation

    C h a p t e r Installation...
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  • Page 17: Assessing The System Requirements

    Assessing the System Requirements WA R N I N G • When preparing to mount the IMPULSE•T drive, lift it by its base. Never lift it by the front cover. • Mount the drive on nonflammable material. • The IMPULSE•T drive generates heat. For the most effective cooling possible, mount it vertically.
  • Page 18 IMPULSE•T System Components And External Devices Optional Drive Components • 120 VAC Interface Card (Part Number T-IF-120VAC) • 24 VAC Interface Card (Part Number T-IF-24VAC) • 48 VAC Interface Card (Part Number T-IF-48VAC) • Quick Start Guide (Part Number 144-25086) As-Required Drive Components •...

  • Page 19: Impulse•T Ratings And Dimensions

    IMPULSE•T Ratings and Dimensions Table 2-1: Ratings and Dimensions Total Heat Voltage Model Wt. in Lbs. Loss (W)** Dimensions in Inches 2006-T 44.7 230V 2010-T 77.5 2012-T 91.7 4002-T 32.4 4004-T 47.3 460V 4005-T 66.3 4009-T 95.1 NOTE: Applications such as high duty cycles in conjunction with high ambient temperatures or other unique environmental conditions can impact drive ratings.

  • Page 20: Installing The Drive

    Installing the Drive The following figure shows the minimum clearances when mounting the drive in standard or side-by- side installations. Figure 2-2: Standard Installation IMPULSE•T Instruction Manual - October 2015...

  • Page 21: Chapter 3:Wiring

    C h a p t e r Wiring...
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  • Page 23: Impulse•T Wiring Practices

    IMPULSE•T 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. • Connect the incoming three-phase AC source to terminals R/L1, S/L2, and T/L3. •...
  • Page 24 • To reverse the direction of rotation, interchange any two motor leads (U/T1, V/T2, or W/T3). Changing R/L1, S/L2, or T/L3 will not affect the shaft rotation direction or change parameter B3- • Use shielded cable for all low-level DC speed reference signals (0 to 10 VDC, 4 to 20 mA). Ground the shield only at the drive side.

  • Page 25: Impulse•T Typical Connection Diagram

    IMPULSE•T Typical Connection Diagram Figure 3-1: IMPULSE•T Typical Connection Diagram IMPULSE•T Instruction Manual - October 2015...
  • Page 26 Terminal Description Table 3-1: Control Circuit Terminals Type Terminal Name Function (Signal Level) R/L1, S/L2, AC power supply input AC power supply input T/L3 U/T1, V/T2, Inverter output Inverter output W/T3 B1, B2 Braking resistor connection Braking resistor connection When connecting optional DC reactor, remove the main circuit short-circuit bar +2, +1 DC reactor connection between +2 and +1.

  • Page 27: 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•T. These devices can be thermal, magnetic, or molded-case circuit breakers (MCCB); or “slow-blow” type fuses such as “CCMR”...
  • Page 28 Table 3-2: Wiring Size (AWG/KCMIL) Control Wiring Control Relay Ground Fuses Power Circuit Wiring Inverse Time Recomm. Rated Time Delay Applicable Recomm. Applicable Recomm. Applicable Recomm. Applicable Molded/Case Continuous Model # Current (A) Input Fuse Gauge Gauge Gauge Gauge Gauge Gauge Gauge Gauge...
  • Page 29 Grounding 1. Connect terminal to the common panel ground. Use ground wiring as specified in “Suggested Circuit Protection and Wire Size” on page 3-7, and keep the length as short as possible. • Ground Resistance: 230 V class; 100 or less, 460 V or greater class; 10 or less. •...
  • Page 30 Wiring the Control Circuit Control Circuit Terminals The IMPULSE•T is shipped standard with a 120 VAC interface card, allowing direct connection of 120 VAC user input devices. The interface card connects to drive terminals S1–S5 and SC. The user input device then connects to terminals S1–S5 and X2 on the interface card. Terminals S1 and S2 are factory programmed for the forward and reverse run commands;...
  • Page 31 Control Board DIP Switches There are three switch settings on the controller board that are used for controller input (S1–S5) polarity and analog input signal control method. The figure below shows the location of these switches and their function along with the default settings. Legend Figure 3-5: DIP Switches Table 3-3: Dip Switch Settings...
  • Page 32 IMPULSE•T Power Terminal Arrangement Table 3-4: Terminal Arrangement 230V Arrangement 460V Arrangement 2006-T 4002-T 2010-T 4004-T 2012-T 4005-T 4009-T Figure 3-6: IMPULSE•T Power Terminal Arrangement IMPULSE•T Instruction Manual - October 2015 3-12...

  • Page 33: Chapter 4: Getting Started

    C h a p t e r Getting Started...
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  • Page 35: Overview

    If you do operate the drive locally, be aware that the crane or hoist will move when you press the RUN button. If you have questions, contact Magnetek. Checks Before Powering After mounting and interconnections are completed, verify: •...

  • Page 36: Using The Keypad

    Using the Keypad All functions of the drive are accessed using the keypad. The operator can enter information using the keypad to configure the drive for their application. This information will be stored into the drive’s memory. Keypad Functions The keypad has a 5-digit LED display. Both numeric and alpha-numeric data can appear on the display.

  • Page 37: Keypad Led And Button Functions

    Keypad LED and Button Functions Some of the keypad buttons, whose functions are described below, are dual-purpose. The dual- purpose keys have one function when used in a view-only mode, and another function when used in a programming mode. Table 4-1: Keys and Displays on the LED Operator Display Name Function...
  • Page 38 Table 4-2: LO/RE LED and RUN LED Indications Flashing Flashing Quickly During run. During During deceleration at a During stop. deceleration to fast-stop. stop. During stop by interlock When a run operation. command is input and frequency reference is 0. When run Run command is command is...

  • Page 39: Parameters

    Parameters Parameters are organized by function group, which will determine how the drive functions. These parameters are programmed in the drive’s software as measurable values or options—both of which will be referred to in this manual as settings. While some of these parameters are associated with one setting, others are tied to a number of possible settings.
  • Page 40 IMPULSE•T Structure of Parameters Group Function Monitor Monitor Fault Maintenance Initialize Initialization Parameters Preset References Reference Limits Application Sequence/Reference Source Acceleration/Deceleration DC Injection Braking Tuning S-Curve Acceleration/ Deceleration V/f Pattern Motor Motor Set-up Digital Inputs Digital Outputs Terminal Analog Inputs Analog Outputs Motor Overload Protection Stall Prevention...

  • Page 41: Parameter Modes

    Parameter Modes All parameters are organized under three modes: Operation Mode Drive operation is enabled. Drive status LED lights. Programming Mode Access to parameters, control method, motion, speed control mode, and passwords are selected. Parameters are set/read. Verify Constants Mode Only parameters that have been changed from the factory default settings are shown here.

  • Page 42: Initialization Set-Up

    Initialization Set-up Parameter Access Level (A1-01) This parameter controls the level of access for all the parameters in the drive. Using this parameter controls the “masking” of parameters according to the access level selected. There are two access levels available - ADVANCED and OPERATION ONLY. When the access level is set to ADVANCED (A1-01 = 0002), it will allow access to all parameters outlined in this manual.

  • Page 43: X-Press Programming

    Speed Reference Selection (A1-04) This parameter will automatically define the input terminals for the selections listed below. See Table 4-8 (X-Press Programming) for details. Table 4-6: Speed Reference Settings Setting Description 2-Speed Multi-Step 3-Speed Multi-Step 5-Speed Multi-Step 2-Step Infinitely Variable Uni-Polar Analog Initialize Parameters (A1-05) Use this parameter to reset the drive to user-specified initial values or clear an oPE04 fault.
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  • Page 45: Chapter 5: Programming Features

    C h a p t e r Programming Features...
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  • Page 47: Application

    Application The application parameters control the acceleration and deceleration characteristics, as well as any preset frequencies the system will require for operation. Application parameters included in this section are listed below: • B1 Preset References • B2 Reference Limits • B3 Sequence/Reference Source •...

  • Page 48: Reference Limits

    Reference Limits These parameters will limit the frequency range as a percentage of maximum output frequency (E1- 04). Table 5-3:Reference Limit Parameter Settings Parameter Initial Access Name Function Range Code Value Level B2-01 Frequency Reference Sets as a percentage of the 0.0–110.0% 100.0 Upper Limit maximum output frequency (E1-...

  • Page 49: Sequence/Reference Source

    If you do operate the drive locally, be aware that the crane or hoist will move when you press the RUN button. If you have questions, contact Magnetek. Stopping Method B3-03 selects the stopping method suitable for the particular application.
  • Page 50 Decel to Stop (B3-03 = 00) Upon removal of the FWD or REV run command, the motor decelerates at a rate determined by the time set in deceleration time 1 (B5-02) and DC injection braking is applied after the DC injection start frequency, 0.5 Hz, has been reached.

  • Page 51: Acceleration/Deceleration

    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 Initial Access Name Function Range Code Value Level B3-04 Reverse Oper Reverse motor direction 00, 01 00 Normal Rotation 01 Exchange Phases Acceleration/Deceleration Acceleration time sets the time necessary for the output frequency to accelerate from 0 Hz to...

  • Page 52: Tuning

    Tuning These parameters help tune the motor for your application, which includes S-Curve characteristics for smoother transition during machine acceleration and deceleration. Below are the parameters included in this section. • D1 DC Injection • D9 S-Curve Acceleration/Deceleration DC Injection DC Injection can be used to stop a motor whose rotational direction is uncertain at start-up.

  • Page 53: S-Curve Acceleration/Deceleration

    S-Curve Acceleration/Deceleration An S-Curve pattern is used to reduce shock and provide smooth transitions during motor 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 54: Motor Parameters

    Motor Parameters Motor data, such as full load amps and V/f pattern, are selected with the following parameters. These parameters include the ability to select and set-up custom V/f patterns for the type of motor used. • E1 V/f Pattern •...
  • Page 55 Table 5-11: Inverter Voltage Overvoltage Trip Braking Transistor Inverter E1-01 Setting Voltage Trip Reset 150-255 400V 380V 380V 375V 400 800V 760V 760V 750V <400 720V 680V 660V 650V Table 5-12: V/f Parameters Parameter Initial Access Name Function Range Code Value Level E1-04...

  • Page 56: Motor Set-Up

    Table 5-13: Sample Voltage/Frequency Pattern Options for 230 V Class E1-04 E1-05 E1-06 E1-07 E1-08 E1-09 E1-10 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 60.0 230.0 60.0...

  • Page 57: Terminal Parameters

    Terminal Parameters There are both digital and analog inputs and outputs that can be programmed for customized operation and sequencing. These include input and output terminal selection along with serial communication. Listed below are the parameters in this section that are customizable for your system.

  • Page 58: External Fault Response Selection

    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 (H1-01 to H1-05), an external fault response must be selected. The table below shows the possible selections for an external fault response. Table 5-17:External Fault Response Selection External Fault Selection Input Level...

  • Page 59: Digital Output

    Digital Output The IMPULSE•T has one multi-function control output (one relay) for indicating various conditions. The following table lists the function selections for the multi-function contact outputs. Table 5-18:Digital Output Parameter Settings Parameter Initial Access Name Function Range Code Value Level H2-01 Output Contactor (MC-...

  • Page 60: Analog Output

    Analog Output The IMPULSE•T has one analog output for the external monitoring of drive conditions. Table 5-20:Analog Output Parameter Settings Parameter Initial Access Name Function Range Code Value Level H4-01 Terminal AM Select Analog output selection for 101–113 Terminal AM. 101 Frequency Reference 102 Output Frequency...

  • Page 61: Protection Parameters

    Protection Parameters The IMPULSE•T has the ability to protect both the drive’s hardware and motor by allowing various means to detect and take corrective action when a condition occurs. These include motor overload detection, torque detection, the ability to perform a self-diagnostic check, and then resume operation after a fault is cleared.

  • Page 62: L1-02 Motor Overload Time Const

    Parameter Initial Access Name Function Range Code Value Level L1-02 Motor Overload Time Time for OL1 fault when motor 0.1–5.0 min current is 150% of the motor Const rated current. Hot start Figure 5-6: Motor Protection Operation Time L1-13 Overload Operation Determines whether or not to 00–01 Selection...

  • Page 63: Stall Prevention

    Stall Prevention C A U T I O N This function automatically adjusts the output frequency, acceleration and/or deceleration rates in order to continue operation without tripping or “stalling” the inverter. Table 5-22:Stall Prevention Parameter Settings Parameter Initial Access Name Function Range Code...
  • Page 64 The stall prevention/current limit level during acceleration is set as a percentage of inverter rated current. During acceleration, if the output current exceeds this current limit level (L3-02), acceleration stops and frequency is maintained. When the output current decreases below this current level (L3-02), acceleration resumes.

  • Page 65: Hardware Protection

    Hardware Protection The IMPULSE•T comes equipped with a number of built-in functions designed to protect the inverter and its components from damage. Table 5-23:Hardware Protection Parameter Settings Parameter Initial Access Name Function Range Code Value Level L8-05 Input Phase Loss Input phase loss detection 00, 01 Selection...

  • Page 66: Operator Parameters

    Value Level O2-04 kVA Selection Determines the model number of 60–97 the drive, which is based on the kVA rating. The following in this column are Magnetek model numbers. Not used 60 -- Not used 61 -- 2004-T 62 2A0004...

  • Page 67: Monitor Parameters

    Input Terminal Status O/Adv U1-11 Output Terminal Status Output Terminal Status O/Adv U1-13 Terminal A1 Level External Terminal input level O/Adv U1-14 Flash ID Magnetek software ID number O/Adv *O = Operation; Adv = Advanced IMPULSE•T Instruction Manual – October 2015 5-23...

  • Page 68: Fault Trace

    Parameter Access Name Function Units Code Level* U1-19 Memobus Displays content of MEMOBUS error O/Adv Communication Error U1-28 Software CPU Flash ROM Software ID O/Adv *O = Operation; Adv = Advanced Fault Trace Table 5-27:Fault Trace Parameters Parameter Access Name Function Units Code...

  • Page 69: Chapter 6: Troubleshooting

    C h a p t e r Troubleshooting...
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  • Page 71: 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 72: Drive Faults, Alarms, And Indicators

    Symptom Corrective Action Motor rotation is in the wrong direction. 1. Verify FWD/REV or UP/DN is wired correctly at the interface card. 2. Switch any two leads on U/T1, V/T2, or W/T3 going to the motor. 3. Check parameter B3-04. Motor rotates, but at minimum speed 1.
  • Page 73 Fault Code Fault or Indicator Name/Description Corrective Action CPF08 1. Cycle power to the drive. EEPROM Serial Communications Fault. EEPROM communications are not 2. If the problem continues, functioning properly. replace the drive. CPF11 1. Cycle power to the drive. RAM Fault.
  • Page 74 Fault Code Fault or Indicator Name/Description Corrective Action External fault occurs on Terminal S2. 1. Check constant H1-02 for proper programming. External 2. Check the conditions for input Fault 2 terminal S2 (U1-10). External fault occurs on Terminal S3. 1. Check constant H1-03 for proper programming.
  • Page 75 Fault Code Fault or Indicator Name/Description Corrective Action 1. Reduce the load. Overtorque Detection Level 1 Fault. Current is higher than set value (150%) Overtorque for more than set time (0.1 sec). Det 1 Overvoltage Fault. The DC bus voltage 1.
  • Page 76 Table 6-4: Operator Error Table Code Fault or Indicator Name/Description Corrective Action OPE02 Parameter Setting Range Error. Parameter 1. Change the parameter setting. settings are set outside the operating range. OPE03 Multi-Function Input Setting Fault. Set values 1. Check the settings for H1-01 to other than “F”...
  • Page 77 A p p e n d i x Advanced Parameter Listing...
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  • Page 79: Impulse•T Parameter Listing

    IMPULSE•T Parameter Listing Reference Parameter Parameter Name Default Range Units Page A1-01 Parameter Access Level 0000 0000, 0002 4-10 0000: Operator Only 0002: Advanced A1-03 Select Motion 4-10 00: Traverse A1-04 Speed Reference 00–05 4-11 00: 2 Speed Multi-Step 01: 3 Speed Multi-Step 02: 5 Speed Multi-Step 03: 2 Step Infinitely Variable 04: Analog - Uni-Polar...
  • Page 80 Reference Parameter Parameter Name Default Range Units Page E1-04 Max Frequency 40.00–E1-04 5-11 E1-05 Max Voltage 230: 0.0–255.0 5-11 460: 0.0–510.0 E1-06 Base Frequency 0.00–E1-04 5-11 E1-07 Mid Frequency A 0.00–E1-04 5-11 E1-08 Mid Voltage A 15.0 230: 0.0–255.0 5-11 30.0 460: 0.0–510.0 E1-09...
  • Page 81 Reference Parameter Parameter Name Default Range Units Page H4-03 Terminal AM Bias -999.9–999.9 5-16 L1-01 Motor Overload Fault Select 00–02 5-17 00: Disable 01: Standard Fan Cooled 02: Standard Blower Cooler L1-02 Motor Overload Time Const 0.1–5.0 5-18 L1-13 Overhead Operation Selection 00, 01 5-18 00: Disable...
  • Page 82 Reference Parameter Parameter Name Default Range Units Page U2-02 Last Fault 5-24 U4-01 Elapsed Time 5-24 U4-04 Cooling Fan Maintenance 5-24 U4-05 Capacitor Maintenance 5-24 U4-06 Soft Charge Bypass Relay 5-24 Maintenance U4-07 IGBT Maintenance 5-24 U4-08 Heatsink Temperature 5-24 U4-09 LED Check 5-24...

This manual is also suitable for:

Impulse-t 2010-tImpulse-t 2012-tImpulse-t 4004-tImpulse-t 4005-tImpulse-t 4009-tImpulse-t 4002-t

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