Page 2 Service Information For questions regarding service or technical information contact: 1.866.MAG.SERV (1.866.624.7378) International Service Outside the U.S. and Canada call +1.262.783.3500, press 3. Columbus McKinnon Corporation Locations Magnetek N49 W13650 Campbell Drive Menomonee Falls, WI 53051 Telephone: 800.288.8178 E-mail: field.service@magnetek.com...
Page 3 It is the responsibility of the owners, users and operators of the Magnetek Products to know, understand and follow all of these requirements. It is the responsibility of the employer to make its employees aware of all of the above listed requirements and to make certain that all operators are properly trained.
Page 4 DANGER, WARNING, CAUTION and NOTE Statements Read and understand this manual before installing, operating or servicing this product. Install the product according to this manual and local codes. The following conventions indicate safety messages in this manual. Failure to heed these messages could cause fatal injury or damage products and related equipment and systems.
Page 5: Table Of Contents
Table of Contents Introduction ..............................10 How to Use This Manual......................... 11 General Information ..........................12 1.2.1 Assessing the System Requirements....................12 1.2.2 Assessing the VFD Environment......................12 Specifications............................13 1.3.1 AC Reactor Specifications........................16 1.3.2 S4IF Interface Board Specifications ....................18 1.3.3 S4I and S4IO Option Card Specifications ..................
Page 6 Parameters ............................. 53 4.3.1 Parameter Modes..........................53 4.3.1.1 Operation Mode ......................... 53 4.3.1.2 Programming Mode ........................53 4.3.1.3 Auto-Tuning Mode ........................53 4.3.1.4 Modified Parameters Mode ......................53 4.3.1.5 Menu Structure ........................... 54 4.3.2 Initialization Setup ..........................56 4.3.2.1 Parameter Access Level (A01-01) ..................... 56 4.3.2.2 Control Method (A01-02) ......................
Page 7 5.2.12.4 Clearing a Load Check Alarm (LC) .................... 94 5.2.13 Swift-Lift™ & Ultra-Lift™ ........................95 5.2.13.1 Swift-Lift ............................. 95 5.2.13.2 Ultra-Lift ............................95 5.2.13.3 Adaptive Ultra-Lift ........................95 5.2.13.4 Configuring the Swift-Lift & Ultra-Lift Function ................97 5.2.14 Torque Limit ............................98 5.2.15 Anti-Shock ............................
Page 8 5.6.6 Analog Inputs ........................... 158 5.6.7 Analog Outputs..........................161 5.6.8 Serial Communication Setup......................163 5.6.9 Pulse Train Input/Output ........................165 Protection Parameters .......................... 166 5.7.1 Motor Overload..........................166 5.7.2 Power Loss Ride Thru........................167 5.7.3 Stall Prevention ..........................168 5.7.4 Speed Agree ............................
Page 9 Appendix A: Parameter Listing ..........................227 Appendix B: Standards Compliance ........................245 Electromagnetic Compatibility (EMC) Guidelines Compliance ................. 245 EMC Guidelines Compliance ........................245 EMC Filter Installation ..........................245 Installation Method ..........................245 ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 9...
Page 10: Introduction
1 Introduction WARNING 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 11: How To Use This Manual
•G+ and VG+ Series 4 parameter settings, functions, troubleshooting, and installation details. Use this manual to expand VFD functionality and to take advantage of higher performance features. This manual is available for download on the Magnetek Material Handling document center website at www.columbusmckinnon.com/magnetek.
Page 12: General Information
6. Ensure that the VFD is housed in an appropriate NEMA-rated enclosure. 7. For severe-duty applications (long lifts, for example), ensure that the VFD 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+ &...
Page 13: Specifications
1.3 Specifications Table 1-2: Specification Values and Information - Heavy Duty 230 V 460 V 575 V Model Rated Output Model Rated Output Model Rated Output (-G+/ Output Capacity (-G+/ Output Capacity (-G+/ Output Capacity VG+S4) Current (A) (kVA) VG+S4) Current (A) (kVA) VG+S4)
Page 14 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 (or equivalent) 230 VAC class: 3-phase 200 to 240 VAC 50/60 Hz Rated input power supply 460 VAC class: 3-phase 380 to 480 VAC 50/60 Hz 575 VAC class: 3-phase 500 to 600 VAC 50/60 Hz...
Page 15 Specification Specification Value and Information for All Models Torque limit selection Limiting of Forward, Reverse, and Regen torques; selectable from 0–300% Stall prevention Functions for accel, decel, at-speed, and constant horsepower region VG+: Speed deviation, overspeed, mechanical brake failure, output phase loss, failed-oscillator, encoder disconnect, roll-back detection, micro controller watchdog, internal braking transistor failure, torque output limit, motor overcurrent, VFD Other protection features...
Page 16: Ac Reactor Specifications
1.3.1 AC Reactor Specifications Reactors, both as input (line) and output (load) devices, protect variable frequency drives (VFD), motors, and other load devices against excessive voltage and current. The following guidelines may help determine input and output reactor requirements: • The following tables are only a guideline.
Page 17 Table 1-5: 460 V Class VFD Model Number 460 V Part Number Reactor Fundamental Amps Motor HP (kW) 4001-G+/VG+S4 REA460-1 1 (0.75) 4003-G+/VG+S4 REA460-2 2 (1.5) 4004-G+/VG+S4 REA460-3 3 (2.2) 4005-G+/VG+S4 REA460-5 5 (3.7) 4007-G+/VG+S4 REA460-5 5 (3.7) 4009-G+/VG+S4 REA460-5 5 (3.7) 4014-G+/VG+S4 REA460-7.5...
Page 18: S4If Interface Board Specifications
1.3.2 S4IF Interface Board 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 19: Installation
2 Installation WARNING ® • When preparing to mount the IMPULSE •G+ & VG+ Series 4 VFD, lift it by its base. Never lift the VFD by the front cover, as doing so may cause damage or personal injury. • Mount the VFD on nonflammable material.
Page 20: System Components
2.2 System Components 2.2.1 Standard Components • Interface Board (120 VAC, 42-48 VAC, 24 VAC, or 24 VDC) • PG-X3 Line Driver Encoder Option Card (VG+ only) 2.2.2 Optional VFD Components • DI-A3 Digital DC Input Card • DO-A3 Digital Output Card •...
Page 21: Long-Time Storage And Capacitor Reforming Procedure
Variable frequency drives (VFD) 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 VFD’s functionality not be restored after bus cap reforming. Contact Magnetek Service for questions.
Page 22 Figure 2-1: Long-Time Storage ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 22...
Page 23: Installation Orientation
2.4 Installation Orientation Figure 2-2: Standard Installation Orientation 2.5 Installing the VFD (Recommended Clearances) The following two figures show the recommended minimum clearances when mounting the VFD in standard or side-by-side installations. If the recommended clearances can't be met, decreased airflow may reduce the life of the VFD.
Page 24: Installing The Vfd (Side-By-Side)
2.6 Installing the VFD (Side-by-Side) Models 2003 to 2075, 4001 to 4039, and 5001 to 5027 can take advantage of Side-by-Side installation. It is recommended to set parameter L08-35 = 1 when mounting VFDs in a side-by-side configuration. This provides a more conservative OL2 overload protection.
Page 25: Vfd Derating Data
2.7 VFD Derating Data 2.7.1 Temperature Derating To ensure the maximum performance life, the VFD output current must be derated when it is installed in areas with high ambient temperature or if VFDs are mounted side-by-side in a cabinet. In order to ensure reliable VFD overload protection, set parameters L08-12 and L08-35 according to the installation conditions.
Page 26: Dimensions (Ip00/Open Chassis)
2.8 Dimensions (IP00/Open Chassis) Figure 2-8 Figure 2-6 Figure 2-7 Figure 2-9 Figure 2-10 ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 26...
Page 27 Table 2-1: IP00/Open Chassis Dimensions – 230 V Class Dimensions - inches (mm) Model Total Weight Number Figure Loss lbs (kg) (-G+/VG+S4) (W)* 2003 5.51 (140) 10.24 (260) 5.79 (147) 4.80 (122) 9.76 (248) 7.3 (3.3) 2005 5.51 (140) 10.24 (260) 5.79 (147) 4.80 (122) 9.76 (248)
Page 28 Table 2-2: IP00/Open Chassis Dimensions – 460 V Class Dimensions - inches (mm) Model Total Weight Number Figure Loss (lbs) (-G+/VG+S4) (W)* 4001 5.51 (140) 10.24 (260) 5.79 (147) 4.80 (122) 9.76 (248) 7.5 (3.4) 4003 5.51 (140) 10.24 (260) 5.79 (147) 4.80 (122) 9.76 (248)
Page 29 Table 2-3: IP00/Open Chassis Dimensions – 575 V Class Dimensions - inches (mm) Model Total Weight Number Figure Loss (lbs) (-G+/VG+S4) (W)* 5001 5.51 (140) 10.24 (260) 5.79 (147) 4.80 (122) 9.76 (248) 7.5 (3.4) 48.7 5003 5.51 (140) 10.24 (260) 5.79 (147) 4.80 (122) 9.76 (248)
Page 30: Wiring
3 Wiring 3.1 Wiring Practices WARNING Before you wire the VFD, review the following practices to help ensure that your system is wired properly. • Recommended wire is to be rated for minimum 75°C, 600 VAC, vinyl sheathed. • Ensure that the encoder wiring is less than 300 feet unless fiber optic cables are used. •...
Page 31 • When using more than one transformer for the VFD's power, properly phase each transformer. • 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 32 <1> Set L08-55 to 0 when using an external dynamic braking option (CDBR). ® Figure 3-1: IMPULSE •G+ & VG+ Series 4 Typical Connection Diagram ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 32...
Page 33: Suggested Circuit Protection And Wire Size
3.2 Suggested Circuit Protection and Wire Size In order to comply with most safety standards, 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 circuit breakers (MCCB);...
Page 34 Table 3-2: Wire Sizing for 460 V Class Recommended Circuit Protection Recommended Wire Size (AWG) 1, 4 Model Number Time Delay Time Delay Continuous Inverse Time Molded/ Control Ground (-G+/VG+S4) HD Input Input Fuse Input Fuse Power Circuit Wiring Wiring Copper Case Circuit Breaker (A) Amps...
Page 35 Table 3-3: Wire Sizing for 575 V Class Recommended Circuit Protection Recommended Wire Size (AWG) 1, 4 Model Number Time Delay Time Delay Continuous Inverse Time Molded/Case Control Ground (-G+/VG+S4) HD Input Input Fuse Input Fuse Power Circuit Wiring Wiring Copper Circuit Breaker (A) Amps...
Page 36: Power Circuit Wiring
3.2.1 Power Circuit Wiring ® 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. Connect the three-phase power supply wires to a circuit protection system. See Section 3.2 on page 33. 3.
Page 37: Main Circuit Connection Diagram
3.2.2 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) ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 37...
Page 38 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) ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 38...
Page 39 Figure 3-6: Connecting Main Circuit Terminals (4810 and 41090) ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 39...
Page 40: Terminal Block Configuration
3.2.3 Terminal Block Configuration Figure 3-7 and Figure 3-8 show the different main circuit terminal arrangements. Figure 3-7: Main Circuit Terminal Block Configuration ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 40...
Page 41 <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 Technical Manual November 2020 Page 41...
Page 42: Grounding
3.2.4 Grounding Connect terminal G to the common panel ground. Use ground wiring as specified in Section 3.2 on page 33, and keep the length as short as possible. • Ground Resistance: • For 230V class: 100Ω or less • For 460V class: 10Ω...
Page 43: Insulation Barrier
3.2.5 Insulation Barrier Insulation barriers are packaged with VFD models 4370 through 41090 to provide added protection between terminals. Magnetek recommends using the provided insulation barriers to ensure proper wiring. See Figure 3-11 for instructions on placement of the insulation barriers.
Page 44: Interface Board (S4If)
3.2.6 Interface Board (S4IF) 3.2.6.1 DIP Switches and Jumper Locations 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 Table 3-5: Terminal and Wire Specifications Tightening Torque Wire Range Terminal Symbol...
Page 45: Dip Switch Functions
3.2.6.2 DIP Switch Functions DIP Switches are described in this section. The functions of the DIP switches are shown in the table below. Table 3-6: DIP Switches Name Function Setting Analog Input A2 Signal V: 0 to 10 VDC or -10 to 10 VDC (internal impedance: 20 kΩ) (default) Level I: 4-20mA (internal impedance: 250 Ω) RS-485/RS-422...
Page 46: Control Circuit Terminals
3.2.7 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 Type Terminal Signal Function...
Page 47: Interface Board (S4If) Terminal Diagrams
Type Terminal Signal Function Description Signal Level Digital Output Fault annunciate Terminals MA & MC N/O; closed Form C Relay: Signals Terminals MA-MC: N/O at major faults 250 VAC*, 1 A; 30 VDC, 1 A (cont.) Terminals MB-MC: N/C Terminals MB & MC N/C; open at major faults Analog MFAO 1...
Page 48: Safe Torque Off
3.2.8 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.
Page 49: Wiring The Encoder Circuit
NOTE: 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 50: Encoder Wiring Diagrams And Information
3.3.2 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 or 12 VDC (select via CN3 jumper) Black Blue Gray...
Page 51: Getting Started
Because of the additional potential hazards that are introduced when any VFD is operated locally, we advise you to avoid operating it this way. If the VFD is operated locally, be aware that the crane or hoist will move when the RUN button is pressed. Contact Magnetek with any questions. ®...
Page 52: Keypad Led And Button Functions
Enters parameter values and settings. • Selects a menu item to move between displays. • Displays the phone number for the Magnetek Service department. • Switches VFD control between the keypad (LOCAL) and an external source (REMOTE) for the Run command and frequency reference.
Page 53: Parameters
While some of these parameters are associated with one setting, others are tied to a number of possible settings. Before shipping the VFD, Magnetek programmed initial settings in the VFD’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 VFD.
Page 54: Menu Structure
4.3.1.5 Menu Structure * Refer to parameter list on page 4-8. Figure 4-1: Menu Structure ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 54...
Page 55 Group Function Monitor Fault Trace Monitor Fault History Maintenance Control Monitor Initialization Parameters Initialize User-Defined Parameters Speed References Reference Limits Application Run/Reference Source Acceleration/Deceleration Jump Frequencies Field Forcing Quick Stop Reverse Plug Simulation Micro-Speed End of Travel Limits Phantom Stop Load Sharing/Torque Following Klixon Hook Height Measurement...
Page 56: Initialization Setup
4.3.2 Initialization Setup 4.3.2.1 Parameter Access Level (A01-01) This 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 monitors. User Parameters Allows access to only the parameters programmed to A02-01 through A02-32.
Page 57: X-Press Programming
4.3.2.3 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. See Table 4-6 on page 59, Table 4-7 on page 60, and Table 4-8 on page 61 for X-Press Programming™...
Page 58 WARNING When changing A01-03 or A01-04, MFDI, MFDO, and speed reference parameters will be overwritten by X-Press Programming™ (Table 4-6 on page 59, Table 4-7 on page 60, or Table 4-8 on page 61). All parameter settings must be verified for proper operation. Table 4-5: X-Press Programming I/O Quick Reference A01-04 = Terminal S1...
Page 59: Parameters Changed By X-Press Programming
4.3.2.6 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 RS485/ Uni-Polar Bi-Polar Industrial Multi- Multi- Multi- Infinitely Infinitely RDSI Analog Analog Coms Step Step Step Variable...
Page 60 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 RS485/ Uni-Polar Bi-Polar Industrial Multi- Multi- Multi- Infinitely Infinitely RDSI Analog Analog Coms Step Step Step Variable Variable Coms B01-01 Speed 1 20.00...
Page 61 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 RS485/ Uni-Polar Bi-Polar Industrial Multi- Multi- Multi- Infinitely Infinitely RDSI Analog Analog Coms Step Step Step Variable Variable Coms B01-01 Speed 1 20.00 15.00 6.00...
Page 62: Initialize Parameters (A01-05)
4.3.2.7 Initialize Parameters (A01-05) Use this parameter to reset the VFD to its factory default settings or transfer parameters. 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 63: User Parameters (A02-01 Through 32)
4.3.2.9 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 the A02 parameters can be accessed by the user. To assign a parameter as a user parameter, go to the A02 level in the initialize menu.
Page 64: 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 cannot be performed. Table 4-11: Auto-Tuning Parameter Settings Parameter...
Page 65: Standard Auto-Tune (T01-01 = 0)
4.4.1 Standard Auto-Tune (T01-01 = 0) ® This is a rotational Auto-Tuning method for the IMPULSE •VG+ Series 4 VFD which allows for Auto-Tuning on an unloaded or decoupled motor. This method requires that the motor be unloaded or decoupled from the load with the brake disengaged. The instructions below will provide a step-by-step procedure to complete the non-rotational segment of this Auto- Tune function: 1.
Page 66: Non-Rotational Auto-Tune (T01-01 = 1)
4.4.2 Non-Rotational Auto-Tune (T01-01 = 1) ® A non-rotational Auto-Tuning method has been implemented into the IMPULSE •VG+ Series 4 VFD 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 VFD to calibrate the Motor Rated Slip and No-Load Current.
Page 67: Non-Rotational 2 Auto-Tune (T01-01 = 4)
4.4.4 Non-Rotational 2 Auto-Tune (T01-01 = 4) ® This is a non-rotational Auto-Tuning method for the IMPULSE •VG+ Series 4 VFD which allows for Auto-Tuning without decoupling the motor. This method is recommended when the motor cannot be decoupled, and the Motor Rated Slip is known. If the Motor Rated Slip is not known, then the Non-Rotational 1 (T01-01 = 1) is recommended.
Page 68: Programming Advanced Features
5 Programming Advanced Features 5.1 Speed Parameters The speed parameters control the speed frequencies, acceleration and deceleration characteristics, and reference sources. Speed parameters included in this section are listed below: • B01 Speed References • B02 Reference Limits • B03 Sequence/Reference Source •...
Page 69 Table 5-2: Multi-Step Speed Processing by Multi-Function Digital Input (B01-01–B01-16) Forward/ Fwd/Rev Jog Multi-Step Multi-Step Multi-Step Multi-Step Speed Reverse Fwd/Rev Inch Speed 2 Speed 3 Speed 4 Speed 5 Reference Terminal S1 H01-01–08 = 15, 16, H01-01–08 = 0 H01-01–08 = 1 H01-01–08 = 2 H01-01–08 = 3 or S2...
Page 70: Reference Limits
5.1.2 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 71: Run/Reference Source
5.1.3 Run/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.
Page 72: Stop Method
5.1.4 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 B03-03 Stopping Method Determines stop method. 0, 1, 4, 6 G+: 0* VG+: 6* Decel to Stop (Figure 5-2) Coast to Stop (Figure 5-3)
Page 73: Coast To Stop (B03-03=1)
5.1.6 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. Figure 5-3: Coast to Stop 5.1.7 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 74: Motor Rotation Change
5.1.8 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 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 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...
Page 75: Run Select
5.1.11 Run Select If the run reference/speed reference is switched between serial mode and VFD terminal mode, B03-07 determines action after the switch. Table 5-9: Run Select Parameter Settings Parameter Display Function Range Default B03-07 LO/RE RUN Sel Determines action after switching Run/Speed 0, 1 reference source.
Page 76 Parameter Display Function Range Default B03-15 Ref Source 2 Determines what the VFD will use for 0–4 Frequency Reference. Enabled by H01-0x = 1F. Operator Keypad Terminals Terminals or Analog Input • S4IF Interface Board • S4I Digital Input Option Card •...
Page 77: Acceleration/Deceleration
5.1.12 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 78: Accel/Decel Time Switching Frequency
5.1.13 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 79: Jump Frequencies
5.1.14 Jump Frequencies This function allows the “jumping” of critical frequencies so that the motor can operate without resonant vibrations caused by some machine systems. This function is also used for deadband control. Setting the value to 0.0 Hz disables this function. Table 5-12: Jump Frequencies Parameter Settings Parameter Display...
Page 80: Field Forcing
5.1.15 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 81: Special Functions
5.2 Special Functions Table 5-14: Special Function Usage Access Level (A01-01) Advanced (2) Motion (A01-02) Traverse (0) Standard Hoist (1) Hoist (2) Function/Control Method (A01-03) V/f (0) OLV (2) FLV (3) V/f (0) OLV (2) FLV (3) C01: Quick Stop™ ...
Page 82: Quick Stop
5.2.1 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 83: Reverse Plug Simulation
5.2.2 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 84: Micro-Speed
5.2.3 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. Table 5-17: Micro-Speed Parameter Settings Parameter Display...
Page 85: End Of Travel Limits
5.2.4 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.
Page 86: Phantom Stop
5.2.5 Phantom Stop Phantom Stop allows quick identification of a faulted VFD while stopping other VFDs with Phantom Stop enabled. The Phantom Stop feature is designed to stop the VFD operation using the stopping method selected in C03-10 when a Phantom Fault input (H01-01–H01-08 = 5F or 63) is active. The VFD will indicate a Phantom Fault has occurred by blinking the LED on the RUN key in sequence of two short bursts.
Page 87: Load Sharing Setup Example
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. 2. Weight Limit Input (H01-xx = 12 or 62) — Upper Limit 3 is always active regardless of the setting of parameter C03-11.
Page 88: Hook Height Measurement
5.2.8 Hook Height Measurement ® Hook Height Measurement is an IMPULSE •VG+ Series 4 feature that 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.
Page 89: Electronic Programmable Limit Switches (Epls)
5.2.9 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.
Page 90: Lower Limit/Upper Limit Bypass Mfdi
5.2.10 Lower Limit/Upper Limit Bypass MFDI The Limit Bypass allows for the following without the use of jumpers or re-programming parameters: 1. Ease of testing of the Weighted Upper Limit Switch (UL3) or re-homing the Height Measurement function, and 2. To allow changing of the wire ropes, i.e. spooling all the rope off of the hoist drum. NOTE: The momentary key-switch to operate this function should only be accessible to maintenance personnel, not the crane operator.
Page 91 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 Technical Manual November 2020 Page 91...
Page 92: Load Float
5.2.11 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 VFD to go into Load Float for the time set in C04-01. During Load Float, the VFD will open the brake and hold the motor at a zero position.
Page 93: Load Check Ii Set Up (C05-01 = 09)
5.2.12.3 Load Check II Set Up (C05-01 = 09) The Load Check II set up procedure will quickly measure and calculate the current or torque required at each of the Load Check Zones starting with the rated load suspended. These values will automatically be stored in parameters C05-09 through C05-24 during the Load Check II set up process.
Page 94: Clearing A Load Check Alarm (Lc)
5.2.12.4 Clearing a Load Check Alarm (LC) A Load Check alarm/fault can be reset by pressing the RESET key on the keypad. Table 5-28: Load Check II Parameter Settings Parameter Display Function Range Default C05-01 Load Check Determines whether Load Check is enabled. 0–9 Disabled Disables Load Check II Function...
Page 95: Swift-Lift™ & Ultra-Lift
Parameter Display Function Range Default C05-22 I/T Level 14 Current/Torque for Zone 14 0–250% C05-23 I/T Level 15 Current/Torque for Zone 15 0–250% C05-24 I/T Level 16 Current/Torque for Zone 16 0–250% C05-25 LC Integral Time Integral time used to smooth transitions 0.00–2.55 sec 0.05 C05-26...
Page 96 Table 5-29: Swift-Lift/Ultra-Lift Parameter Settings Parameter Display Function Range Default C06-01 Swift-Lift (V/f and OLV) Determines whether Swift-Lift/Ultra-Lift is 0–4 Ultra-Lift (FLV) enabled. Disabled Enabled Auto Enabled by MFDI Enabled Adaptive Flux Vector NLB only Adaptive by MFDI Flux Vector NLB only C06-02 SwiftLift FWDSpd (V/f Maximum Swift-Lift Forward Speed...
Page 97: Configuring The Swift-Lift & Ultra-Lift Function
Parameter Display Function Range Default C06-14 Motor Speed 2 Sets the Speed 2 point 100–300% C06-15 AUL FWD Offset Adaptive UL torque measurement offset in the 0–100% up direction to allow for deceleration. C06-16 AUL REV Offset Adaptive UL torque measurement offset in the 0–100% down direction to allow for deceleration NOTE: C06-11 through C06-16 are hidden unless C06-10 is set to “Custom”.
Page 98: Torque Limit
5.2.14 Torque Limit ® IMPULSE •G+ and VG+ Series 4 VFDs 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 99 Table 5-30: Torque Limit Parameter Settings Parameter Display Function Range Default C07-01 Trq Limit FWD FORWARD torque limit 0–300% C07-02 Trq Limit REV REVERSE torque limit 0–300% C07-03 Trq Lmt FWD Rgn Regenerative torque limit at FORWARD 0–300% C07-04 Trq Lmt REV Rgn Regenerative torque limit at REVERSE 0–300% C07-05...
Page 100: Anti-Shock
5.2.15 Anti-Shock ® Anti-Shock is a Hoist NLB feature on the IMPULSE •VG+ Series 4 VFD 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 101 Table 5-31: Anti-Shock Parameter Settings Parameter Display Function Range Default C07-12 Anti-Shock Enables or disables the Anti-Shock function. 0–2 Disabled Anti-Shock is disabled always. Enabled Anti-Shock is enabled always. Enbl, Not In MSpd Disables Anti-Shock if Micro-Speed is enabled. C07-13 Enabling Freq Anti-Shock is disabled until the output 0.0–60.0 Hz...
Page 102: Load Brake Hoist (Vg+)
5.2.16 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).
Page 103 Dual Brake Feature The Dual Brake feature is designed for hoist systems with redundant holding brakes. One brake is controlled by an MFDO programmed to 00, and the second brake is controlled by an MFDO programmed to 0A. After a Load Float, during the BE6 (Brake Test) time, one brake is left Open, while the VFD tests that the Closed brake is capable of holding the load.
Page 104 Table 5-32: No Load Brake Parameter Settings Parameter Display Function Range Default C08-01 Torque Comp Time Amount of time for the Torque Comp value to reach 0.00–2.55 sec 1.00 300%. C08-02 IFB OK Time Sets the amount of time to look for the current 0.00–2.55 sec 1.00 feedback to be OK before posting a BE2 alarm.
Page 105 Parameter Display Function Range Default C08-16 Init FWD Brk Trq Initial Brake Release Torque. The percentage of 10–300% forward/up motor torque that must be reached within C08-02 time in order for the brake to release at the start of the run command. (BE2 detection). This occurs in both directions.
Page 106: Emergency Lift (Vg+)
E-Lift is designed to allow for temporary hoisting operations of motors normally equipped with an encoder in Flux Vector control. Always follow instructions given in the E-Lift setup guide, 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.
Page 107 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 108: Digital Input (Di-A3, S4I, Or S4Io) Option Card Setup
5.2.18 Digital Input (DI-A3, S4I, or S4IO) Option Card Setup Selects the digital input controls for either the DI-A3, S4I, or S4IO option when installed. Table 5-34: Digital Input Setup Parameter Settings Parameter Display Function Range Default C09-01 Digital In Sel Provides additional programmable MFDI 0–2, 5 Disabled...
Page 109: Weight Measurement
5.2.19 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 VFD must pause the acceleration, wait for the torque to stabilize, and then perform the weight calculation based on the system tare values.
Page 110: System Tare And Calibration For Weight Measurement
VFD with the use of the VFD’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 111: Slack Cable Detection
5.2.20 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. The Slack Cable Detection is not executed, unless both of the following conditions are true: •...
Page 112: Snap Shaft Detection
Parameter Display Function Range Default C11-05 SLC Delay Time 1 The delay time before the enabled Slack Cable 0.00–2.55 sec. 0.50 Detection can be activated. It corresponds to Slack Cable Detection Speed 1 (C11-04). Prevents false outputs. C11-06 SLC Detect Spd 2 The Frequency Output below which the enabled 0–E01-04 Hz Slack Cable Detection can be activated.
Page 113: Brake Delay Timers
5.2.22 Brake Delay Timers This function is used in trolley or bridge applications. It can reduce the mechanical brake wear when the operator positions a load. This function is available only in traverse mode and B03-03 must be set to 4 (Decel With Timer). Table 5-38: Delay Timers Parameter Settings Parameter Display...
Page 114: Maintenance Timer
5.2.24 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 115: Inch Control
5.2.26 Inch Control The Inch 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). CAUTION A directional input is not needed to enable motor torque. Table 5-42: Inch Control Parameter Settings Parameter Display...
Page 116: Index Control
5.2.27 Index Control ® Index Control is an IMPULSE •VG+ Series 4 feature that 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 117 During Run If the motor is in motion when the Index function is turned ON, the VFD will decelerate to zero and hold the position in Load Float. After a Run command is applied, the VFD will Index the load and hold the position in Load Float after the Index is complete.
Page 118: Tuning
5.3 Tuning • D01 DC Injection Braking • D02 Motor Slip Compensation • D03 Torque Compensation • D04 Automatic Speed Regulator (ASR) Tuning • D05 Torque Control • D08 Dwell • D09 S-Curve Acceleration/Deceleration • D10 Carrier Frequency • D11 Hunting Prevention 5.3.1 DC Injection ®...
Page 119: Motor Slip Compensation
5.3.2 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. A setting of “0.0”...
Page 120: Automatic Speed Regulator (Asr) Tuning
Parameter Display Function Range Default D03-01 Torq Comp Gain Sets the gain for the automatic torque (voltage) 0.00–2.50 1.0* boost function and helps to produce better starting torque. D03-02 Torq Comp Time Sets the torque compensation filter time. 0–60000 ms V/f: 200 OLV: 20 D03-03...
Page 121: Adjusting The Asr Parameters In Flv
5.3.4.1 Adjusting the ASR Parameters in FLV The VFD is preset to use ASR settings D04-01/02 over the entire speed range in Flux Vector. 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.
Page 122: Flux Vector (Flv)
Table 5-47: ASR Tuning Parameter Settings Parameter Display Function Range Default D04-01 ASR P Gain 1 Sets the proportional gain of the speed control 0.00–300.00 20.00 loop (ASR). D04-02 ASR I Time 1 Sets the integral time of the speed control loop 0.000–10.000 sec 0.500 (ASR).
Page 123: Torque Control
The switching frequency (D04-07) can also be controlled with a digital input programmed to “ASR gain switch” (H01-xx = 37). When the terminal is open, the VFD uses the ASR gain level set by the pattern in Figure 5-19 above. When the terminal closes, D04-03 is used. The integral time set to D04-02 is used to change linearly between these settings, as shown in Figure 5-20 below.
Page 124: Speed/Torque Control Switching
5.3.5.1 Speed/Torque Control Switching Speed control or torque control is used in traverse applications and can be selected “on the fly” with the VG+ VFD by using the digital input speed/torque control selection (H01-xx = 34). Table 5-49: Speed/Torque Control Switch Parameters Terminal Parameter Setting...
Page 125: Dwell
5.3.6 Dwell 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 Parameter Display Function Range Default D08-01 Dwell Ref @ Start Sets Dwell frequency reference at start.
Page 126: S-Curve Acceleration/Deceleration
5.3.7 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. Table 5-51: S-Curve Acceleration/Deceleration Parameter Settings Parameter Display...
Page 127: Carrier Frequency
The Carrier Frequency group provides the ability to modify the VFD’s output carrier frequency and VFD overload level. CAUTION Consult Magnetek for VFD derating before modifying the D10 group parameters. Failure to do so may result in equipment damage. Table 5-52: Carrier Frequency Parameter Settings...
Page 128: Hunting Prevention
5.3.9 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.
Page 129: Motor Parameters
5.4 Motor Parameters • E01 V/f Pattern • E02 Motor Setup • E03 Test Mode Configuration 5.4.1 Voltage/Frequency Pattern WARNING VFD input voltage (not motor voltage) must be set in E01-01 for the protective features of the VFD to function properly.
Page 130 An OPE10 error will occur if the following conditions are not met: E01-05 ≥ E01-12 ≥ E01-13 ≥ E01-08 ≥ E01-10 E01-04 ≥ E01-11 ≥ E01-06 ≥ E01-07 ≥ E01-09 NOTE: When using the Flux Vector control method, the V/f pattern voltage values will be adjusted by the Auto- Tuning function.
Page 131 Parameter Display Function Range Default E01-05 Max Voltage Maximum Voltage 230 V: 0.0–255.0 Determined by O02-04 460 V: 0.0–510.0 575 V: 0.0–733.1 E01-06 Base Frequency Motor Base Frequency 0.0–150.0 Hz 60.0 E01-07 Mid Frequency A Midpoint Output Frequency A 0.0–150.0 Hz Determined by E01-03 E01-08...
Page 132 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 133 Table 5-58: Voltage/Frequency (V/f) Pattern Options (460 V) E01-04 E01-05 E01-06 E01-07 E01-08 E01-09 E01-10 E01-11 E01-12 E01-13 E01-03 60.0 460.0 60.0 29.9 16.2 60.0 460.0 60.0 32.2 18.4 60.0 460.0 60.0 34.6 20.8 60.0 460.0 60.0 36.8 23.0 60.0 460.0 60.0 39.1...
Page 134 Table 5-59: Voltage/Frequency (V/f) Pattern Options (575 V) E01-04 E01-05 E01-06 E01-07 E01-08 E01-09 E01-10 E01-11 E01-12 E01-13 E01-03 60.0 575.0 60.0 37.5 20.3 60.0 575.0 60.0 40.3 23.0 60.0 575.0 60.0 43.3 26.0 60.0 575.0 60.0 46.0 28.8 60.0 575.0 60.0 49.0...
Page 135: Motor Setup
5.4.2 Motor Setup The E02 parameter group defines the motor characteristics. Normally, the default settings for E02 parameters are determined by kVA selection (O02-04). In flux vector and open loop vector, the E02 parameters will be set automatically during auto-tuning. At minimum, the motor rated current should be entered into E02-01. If rotational auto-tuning cannot be performed, E02-02 and E02-05 can be calculated using the motor’s nameplate information or by performing non-rotational auto-tuning.
Page 136: Test Mode Configuration
5.4.3 Test Mode Configuration Test Mode is a troubleshooting aid that is intended for troubleshooting Flux Vector control method problems. This feature cannot be left on indefinitely, as it will generate a fault after being on for a total accumulated time of ten minutes.
Page 137: Option Card Parameters
5.5 Option Card Parameters • F01 Encoder Feedback (PG-X3) Option Card Setup • F02 Analog Input (AI-A3) Option Card Setup • F04 Analog Output (AO-A3) Option Card Setup • F05 Digital Output (DO-A3 or S4IO) Option Card Setup • F06 Profibus-DP (SI-P3) Option Card Setup •...
Page 138 Parameter Display Function Range Default F01-14 PG2 #Gear Teeth2 Sets the gear ratio between the motor shaft and the 0–1000 encoder (PG). A gear ratio of 1 will be used if F01-13 or F01-14 are set to 0. F01-15 PG2 Output Ratio Sets the division ratio for the pulse monitor.
Page 139: Analog Input (Ai-A3) Option Card Setup
5.5.2 Analog Input (AI-A3) Option Card Setup Sets CH1 to CH3 input functions when AI-A3 option card is connected. When the 3CH individual input is used, parameter B03-01 is automatically set to “1” (frequency reference from control circuit terminal). The reference selection, which is selected by a multi-function digital input (H01-xx= 1F), is disabled when using the AI-A3 option card.
Page 140 Table 5-65: Parameter Settings for F04-01 and F04-03 Display Display Not Used 165 PG Output Freq 101 Frequency Ref 184 NLB State* 102 Output Freq 185 NLB Rel Trq* 103 Output Current 408 Heatsink Temp 105 Motor Speed* 416 Motor OL1 Level 106 Output Voltage 417 Drive OL2 Level 107 DC Bus Voltage...
Page 141: Digital Output (Do-A3 Or S4Io) Option Card Setup
5.5.4 Digital Output (DO-A3 or S4IO) Option Card Setup Selects the multi-function digital output settings for the DO-A3 and S4IO option cards. Table 5-66: DO-A3/S4IO Parameter Settings Terminal Designation Parameter Display Range Default DO-A3 S4IO F05-01* DO Ch1 Select M1-PC O1-O2 0–148 F05-02*...
Page 142 Table 5-67: DO-A3 Output Mode Selection F05-09 Output Type Terminals Output Contents 8 –Channel TD5 – TD11 OverCurrent (SC, OC, GF) Individual (Fixed TD6 – TD11 OverVoltage (OV) Data) TD7 – TD11 Drive Overload (OL2, OH, OH1) TD8 – TD11 Fuse Blown (PUF) TD9 –...
Page 143: Profibus-Dp (Si-P3) Option Card Setup
5.5.5 Profibus-DP (SI-P3) Option Card Setup Settings for the Profibus-DP communication option card SI-P3. Table 5-68: SI-P3 Parameter Settings Parameter Display Function Range Default F06-01 Comm Bus Flt Sel Stopping method at communication error. 0–4 Decel to Stop Coast to Stop Fast-Stop Use B3-03 Method Alarm Only...
Page 144 Parameter Display Function Range Default F06-31 PB Clear Select Determines the operation when a “Clear 0, 1 Mode” command is received on the Profibus- DP option Card Reset to Zero Resets VFD operation with a Clear mode command. Hold Prev Value Maintains the previous operation state when Clear mode command is given.
Page 145: Ethernet/Ip (Si-En3) And Modbus Tcp/Ip (Si-Em3) Option Card Setup
Parameter Display Function Range Default F06-57 DN Current Scale Sets the scaling factor for the output current -15–15 monitor in DeviceNet. F06-58 DN Torque Scale Sets the scaling factor for the torque monitor -15–15 in DeviceNet. F06-59 DN Power Scale Sets the scaling factor for the power monitor -15–15 in DeviceNet.
Page 146 Parameter Display Function Range Default F07-16 CommLoss Tout Sets the time-out value for communication 0.0-30.0 sec loss detection. F07-17 EN Speed Scale Sets the scaling factor for the EtherNet/IP -15–15 speed setting/monitor F07-18 EN Current Scale Sets the scaling factor for the EtherNet/IP -15–15 output current setting/monitor F07-19...
Page 147: Terminal Parameters
5.6 Terminal Parameters • H01 Digital Inputs • H02 Digital Outputs • H03 Analog Inputs • H04 Analog Outputs • H05 Serial Communication Setup • H06 Pulse Input/Output 5.6.1 Digital Inputs ® The IMPULSE •G+ and VG+ Series 4 has eight multi-function digital inputs for the setup of numerous functions. The following table lists the function selections for the multi-function digital inputs (terminals S1 to S8) and indicates the control methods during which each function can be enabled.
Page 148 Table 5-71: Multi-Function Digital Inputs (MFDI) selectable for H01-0x and C09-0x Display Function Multi-Step Ref 2 Multi-Step Reference 2 Multi-Step Ref 3 Multi-Step Reference 3 Multi-Step Ref 4 Multi-Step Reference 4 Multi-Step Ref 5 Multi-Step Reference 5 Speed Hold 2 Speed Hold 2 (2nd Step of Three-Step Infinitely Variable) Accel Command Accel Command (2nd Step of Two-Step Inf.
Page 149 Display Function 3A MFAI Enable On: Terminals specified in H03-14 are enabled. Off: Disregards the input signal to the analog terminals. The terminals not set in H03-14 will always be enabled. 3F Fault Reset On: Resets VFD faults 41 SnapShaft Disabl When input is ON, Snap Shaft Detection is disabled.
Page 150: F1 And F2 Keys Function Selection
5.6.2 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 151: Digital Outputs
5.6.3 Digital Outputs ® The IMPULSE •G+ and VG+ Series 4 has three built-in multi-function digital outputs for indicating various conditions. 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. Table 5-74: Digital Outputs Parameter Settings Parameter Display...
Page 152 Table 5-75: Multi-Function Digital Outputs (MFDO) selectable for H02-0x and F05-0x Display Function 0 Brake Release* ON: VFD is commanding the brake to be Open OFF: VFD is commanding the brake to be Closed 1 Zero Speed* ON: Motor Speed < D01-01 or E01-09 2 Fref/Fout Agree1 ON: Output frequency (U01-02) is within frequency reference (U01-01) ±...
Page 153 Display Function 1A Forward Dir ON: During Forward/Up operation OFF: Running in Reverse/Down direction or baseblock 1B Reverse Dir ON: During Reverse/Down operation OFF: Running in Forward/Up direction or baseblock 1C Swift/Ultra-Lift Mode ON: VFD is operating in Swift-Lift/Ultra-Lift OFF: VFD is not operating in Swift-Lift/Ultra-Lift 1D Brk Trans Fault ON: VFD detects a brake transistor failure OFF: Normal operation...
Page 154 Display Function 2D Lower Limit 1 ON: LL1 is detected OFF: Normal operation 2E Lower Limit 2 ON: LL2 is detected OFF: Normal operation 30 Lower Limit ON: LL1 or LL2 is detected OFF: Normal operation 31 Up/Low Limit ON: UL1, UL2, UL3, LL1, or LL2 is detected OFF: Normal operation 32 Snap Shaft ON: VFD has detected a Snap Shaft...
Page 155: Digital Outputs-Alarm/Fault Annunciate (H02-01-03=40)
5.6.4 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 be used for Digital Outputs—Fault Annunciate; it is normally assigned to a brake output.
Page 156 Table 5-77: Fault Annunciate Worksheet First digit from the left Second digit from the left Set 1 Binary Number First digit from the left Second digit from the left Set 2 Binary Number First digit from the left Second digit from the left Set 3 Binary Number...
Page 157: External Fault Response Selection
Table 5-78: Binary to Hexadecimal Conversion Binary Number Hexadecimal Number Binary Number Hexadecimal Number 0000 1000 0001 1001 0010 1010 0011 1011 0100 1100 0101 1101 0110 1110 0111 1111 5.6.5 External Fault Response Selection It is sometimes desirable to have at least one external fault input to the VFD. To properly program a multi-function input (H01-01 to H01-08) for this purpose an external fault response must be selected.
Page 158: Analog Inputs
5.6.6 Analog Inputs ® The IMPULSE •G+ and VG+ Series 4 has three built-in analog inputs for the external input of numerous references and limits. VFD analog input capabilities can be increased with the installation of an AI-A3 option card. Table 5-80: Analog Inputs Parameter Settings Parameter Display...
Page 159 Parameter Display Function Range Default H03-16 TerminalA1Offset Adds an offset when the analog signal to -500–500 terminal A1 is 0V H03-17 TerminalA2Offset Adds an offset when the analog signal to -500–500 terminal A2 is 0V H03-18 TerminalA3Offset Adds an offset when the analog signal to -500–500 terminal A3 is 0V * Initial value is determined by X-Press Programming (Table 4-6 on page 59, Table 4-7 on page 60 or Table 4-8 on page 61).
Page 160 Table 5-82: Option Selections for H03-02, H03-06, and H03-10 (V/f) Display Function 0 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) 1 Frequency Gain Analog frequency bias will be multiplied with the analog frequency reference gain.
Page 161: Analog Outputs
5.6.7 Analog Outputs ® The IMPULSE •G+ and VG+ Series 4 has two built-in analog outputs for the external monitoring of VFD conditions. VFD analog output capabilities can be increased with the installation of an AO-A3 option. Table 5-83: Analog Outputs Parameter Settings Parameter Display Function...
Page 162 Parameter Display Function Range Default H04-01 606 Voltage Ref (Vd) 000–630 607 ACR(q) Output 608 ACR(d) Output 611 Iq Reference 612 Id Reference 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...
Page 163: Serial Communication Setup
5.6.8 Serial Communication Setup ® The IMPULSE •G+ and VG+ Series 4 uses terminals R+/R-, S+/S- to communicate the MODBUS RTU (RS-485/ 422) protocol. Cycle power after changing serial format parameters. Table 5-84: Serial Communication Setup Parameter Settings Parameter Display Function Range Default...
Page 164 Parameter Display Function Range Default H05-11 Enter CommandSel 0, 1 Enter Required VFD 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 Run &...
Page 165: Pulse Train Input/Output
5.6.9 Pulse Train Input/Output Pulse Input and Output provides speed control capabilities via the RP and MP terminals. Table 5-85: Pulse Input/Output Parameter Settings Parameter Display Function Range Default H06-01 Pulse Input Sel Terminal RP pulse input 0, 5–7 Frequency Ref Set B03-01 = 4 (pulse input) to enable this input.
Page 166: Protection Parameters
5.7 Protection Parameters • L01 Motor Overload • L02 Power Loss Ride Thru • L03 Stall Prevention • L04 Reference Detection • L05 Test Mode • L06 Torque Detection • L08 Hardware Protection • L09 Automatic Fault Reset • L09 Fault Latch 5.7.1 Motor Overload ®...
Page 167: Power Loss Ride Thru
Parameter Display Function Range Default L01-03 Mtr OH Alarm Sel Operation when the motor temperature 0–3 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 168: Stall Prevention
5.7.3 Stall Prevention Table 5-88: Stall Prevention Parameter Settings Parameter Display Function Range Default L03-01 StallP Accel Sel Sets how the Stall Prevention will function during 0–2 acceleration. (G+ only) Disabled General Purpose Acceleration is paused as long as the current is above the L03-02 setting.
Page 169: Speed Agree
Parameter Display Function Range Default L03-23 CHP Stall P Sel This function reduces the Stall Prevention during run 0, 1 level in the constant power range. (G+ only) Lvl set in L3-06 Sets the Stall Prevention level that is used throughout the entire frequency range.
Page 170 Table 5-89: Speed Agree Parameters Parameter Display Function Range Default L04-01 Spd Agree Level Sets the detection level for the desired speed 0.0–150.0 Hz 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 agree 1...
Page 171: Test Mode
5.7.5 Test Mode Test Mode is a troubleshooting aid that is intended for troubleshooting Flux Vector problems. 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 172 Table 5-93: Torque Detection Setting Descriptions Settings Description Torque detection is disabled (factory default). Overtorque detection is enabled whenever at the speed agree level (when VFD is not accelerating or decelerating). Continue running after detection (OT1 alarm). Overtorque detection is enabled always. Continue running after detection (OT1 alarm). Overtorque detection is enabled whenever at the speed agree level.
Page 173 Table 5-95: Torque Detection 2 Select Descriptions Settings Description Overtorque/undertorque detection is disabled (factory default). Overtorque detection is enabled whenever at the speed agree level (when VFD is not accelerating or decelerating). Continue running after detection (OT2 alarm). Overtorque detection is enabled always. Continue running after detection (OT2 alarm). Overtorque detection is enabled whenever at the speed agree level.
Page 174 Table 5-97: Mechanical Fatigue Selection Description Settings Description Mechanical Weakening Detection disabled (factory default). Continue running (alarm only). Detected when the speed (signed) is greater than L06-09. Continue running (alarm only). Detected when the speed (not signed) is greater than L06-09. Interrupt VFD output (fault).
Page 175: Hardware Protection
5.7.7 Hardware Protection ® The IMPULSE •G+ and VG+ Series 4 comes equipped with a number of built-in functions designed to protect the VFD and its components from damage. Table 5-99: Hardware Protection Parameter Settings Parameter Display Function Range Default L08-02 OH Pre-Alarm Lvl Sets the heatsink temperature level for protection...
Page 176 Parameter Display Function Range Default L08-18 Soft CLA Sel Software current limit 0, 1 Disabled Enabled L08-19 Fc Red dur OHAlm Specifies the frequency reference reduction gain 0.1–0.9 Hz at overheat pre-alarm when L08-03 = 4. L08-32 MC,FAN Fault Sel MC, FAN configure the operation of power if it 0–4 detects a warning alarm...
Page 177: Automatic Fault Reset
5.7.8 Automatic Fault Reset ® When a fault occurs during operation, the IMPULSE •G+ and VG+ Series 4 can automatically reset the fault. Table 5-100: Automatic Reset Parameter Settings Parameter Display Function Range Default L09-01 Reset Select Activates the fault auto-reset function. 0, 1 Disabled Enabled...
Page 178 Example: Enable auto-reset for UV1 and CE faults. Table 5-101: Auto-Reset Programming Digit 4 Digit 3 Digit 2 Digit 1 Binary L09-04 Binary L09-05 Table 5-102: Auto-Reset Programming Summary L09-04 Binary L09-05 Binary Digit 4 0000 Digit 4 0000 Digit 3 0000 Digit 3 0000...
Page 179: Fault Latch Selection
5.7.9 Fault Latch Selection The Fault Latch function allows 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 the methods explained below.
Page 180: Keypad Parameters
5.8 Keypad Parameters • O01 Monitor Selection • O02 LO/RE Key Selection • O03 Maintenance History • O04 Copy Function 5.8.1 Monitor Selection The home level of the keypad allows the viewing of four monitor variables. They are Fref, Fout, Iout, and User- Selected monitor.
Page 181 Parameter Display Function Range Default O01-01 150 Hook Height 151 Motor Revolution 152 MaintenanceTimer 153 Index Count 154 Term RP Inp Freq 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...
Page 182 Parameter Display Function Range Default O01-02 Power-On Monitor Selects the monitor to be displayed on the 1–5 keypad 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 183: Keypad Key Selection
Range Default O02-01 LO/RE Key Pressing the LO/RE Key once displays: “Call 0, 1 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 time:...
Page 184 Parameter Display Function Range Default O02-04 75 2_0250 2215-G+/VG+S4 00–FF 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 9A 4_0023 4018-G+/VG+S4 9C 4_0031...
Page 185 Parameter Display Function Range Default O02-04 D3 5_0077 5062-G+/VG+S4 00–FF D4 5_0099 5077-G+/VG+S4 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 used 0, 1 when the frequency reference is set by the keypad.
Page 186: Maintenance History
5.8.3 Maintenance History Table 5-108: Clear History Parameter Settings Parameter Display Function Range Default O03-01 Elapsed Time Set Sets the value for the cumulative operation 0–9999 x 10 hr time of the VFD in units of 10 hours. Cumulative time can be viewed using monitor Cumulative Operation Time (U04- 01).
Page 187: Copy Function
5.8.4 Copy Function Table 5-109: Copy Function Parameter Settings Parameter Display Function Range Default O04-01 Copy Function Sel Copy parameters to/from keypad 0–3 COPY SELECT INV → OP READ VFD → Keypad OP → INV WRITE Keypad → VFD OP ↔ INV VERIFY Keypad ↔...
Page 188 A successful COPY of the parameter values will display: An error may occur while writing the parameter values to the VFD. If an error is displayed, press any key to return to parameter O04-01. Error displays and their meanings are covered in Section 6.5.1 on page 222. It is possible to compare the parameter values stored in the keypad with the parameter values currently in the VFD by using the VERIFY function.
Page 189: Monitor Parameters
5.9 Monitor Parameters • U01 Monitor • U02 Fault Trace • U03 Fault History • U04 Maintenance • U06 Control Monitor Table 5-110: Monitor Parameters Parameter Display Function Units U01-01 Frequency Ref Frequency Reference U01-02 Output Freq Output Frequency U01-03 Output Current Output Current U01-04...
Page 190 Parameter Display Function Units U01-12 Int Ctl Sts 1 Operation Status U01-14 CPU 1 SW Number Firmware version 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 Primary freq.
Page 191 Parameter Display Function Units U01-60 PG CH1 Count Displays the raw PG Channel 1 pulse count Pulses 4 pulses = 1 ppr of F01-01 U01-61 PG CH2 Count Displays the raw PG Channel 2 pulse count Pulses 4 pulses = 1 ppr of F01-01 U01-63 PG CH1 Freq Displays the current input frequency on PG Channel 1...
Page 192 Table 5-111: Fault Trace Parameters Parameter Display Function Units U02-01 Current Fault Display the most current fault detected before being reset. U02-02 Last Fault Displays most recent fault after being reset. U02-03 Frequency Ref Freq ref when fault was detected. U02-04 Output Freq Output freq when fault was detected.
Page 193 Table 5-112: Fault History Parameters Parameter Display Function Units U03-01 Last Fault Displays the first most recent fault. U03-02 Fault Message 2 Displays the second most recent fault. U03-03 Fault Message 3 Displays the third most recent faults. U03-04 Fault Message 4 Displays the fourth most recent fault.
Page 194 Table 5-113: Maintenance Parameters Parameter Display Function Units U04-01 Drv Elapsed Time Displays the cumulative operation time of the VFD. 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 195 Parameter Display Function Units U04-37* OH Alarm Axis Displays the module where the oH alarm occurred as a binary number. 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.
Page 196: Troubleshooting
6 Troubleshooting 6.1 Troubleshooting the VFD 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. 6.1.1 Maintenance and Inspection ®...
Page 197 Table 6-2: Motor Related Issues and Corrective Actions Symptom Corrective Action Analog frequency reference is not stable. (drifting) 1. Stabilize the analog source. 2. Increase H03-13. 3. Increase B05-01 or B05-02. No motor rotation. 1. Verify that power is on (Charge LED). 2.
Page 198 Code Fault/Alarm Description Corrective Action Fault Alarm Torque Proving Fault. The BE1 fault indicates 1. Increase the value of C08-21. that the VFD has released the brake, but not Rollback detect 2. See Section 6.2 on page 210. started to accelerate the motor when it detects excessive encoder feedback.
Page 199 Code Fault/Alarm Description Corrective Action Fault Alarm Brake Proving Alarm. The BE6 alarm indicates 1. Check the brake. (flashing) that the VFD has commanded the brake to set but Brake Stop 2. See Section 6.2 on page 210. it has detected more than the expected encoder feedback.
Page 200 CPF01 2. If the problem continues, keypad is damaged. replace the control board or the entire VFD. Contact Magnetek for instructions on replacing the control board. 3. Replace the keypad if it is damaged. CPF02 A/D Conversion Error. An A/D conversion error 1.
Page 201 VFD. being saved to the VFD. 2. If the problem continues, replace the control board or the entire VFD. Contact Magnetek for instructions on replacing the control board. Parameter Save Interruption 1. Reinitialize the VFD (A01-03 = 5432).
Page 202 Code Fault/Alarm Description Corrective Action Fault Alarm CPF26– Control Circuit Error. 1. Cycle power. CPF34 2. Ensure that the terminal board is seated properly. CPF40– 3. Set A01-05 = 5550. CPF45 4. Replace control board and/or terminal board. Speed Deviation Fault. Occurs when the 1.
Page 203 Code Fault/Alarm Description Corrective Action Fault Alarm External fault occurs on Terminal S7. 1. Check H01-07 for proper programming. External Fault 7 Alarm or fault defined by the External Fault 2. Check the condition of the Selection table (Table 5-79 on page 157). input terminal S7.
Page 204 Code Fault/Alarm Description Corrective Action Fault Alarm Output Current Imbalance. One or more of the 1. Check for faulty wiring or poor/ phases in the output current are lost. loose connections on the Output Current output side of the VFD. Imbalance 2.
Page 205 Code Fault/Alarm Description Corrective Action Fault Alarm Motor Overload Fault. VFD output exceeded the 1. Ensure VFD is programmed motor overload level. with proper motor full load Motor Overloaded Amps (E02-01). Alarm or fault defined by L06-08. 2. Reduce the load. VFD Overload Fault.
Page 206 Code Fault/Alarm Description Corrective Action Fault Alarm PULSDEV Pulse Deviation. The pulse input into terminal 1. During operation, verify that RP compared to the pulse output from terminal there is an incoming pulse Pulse Deviation MP is greater than the percentage programmed signal on the RP terminal, into H06-09.
Page 207 Code Fault/Alarm Description Corrective Action Fault Alarm Upper Limit 1—SLOW DOWN Indicator. Upper 1. May not require corrective Limit 1—SLOW DOWN switch status is changed. action. Upper Limit 1 Err 2. Check the limit switches location. 3. Check the limit switches condition.
Page 208 VFD. For instructions on replacing the gate driver board, contact Magnetek or a Magnetek representative. Output Voltage Detection Fault. 1. Replace the VFD. Problem detected with the voltage on the output side of the VFD.
Page 209 Code Error/Name Description Corrective Action OPE11 Carrier Frequency Parameter Error. 1. Check Parameters D10-01 to D10-05. CarrFrq/ON-Delay OPE13 Sync & Ultra-Lift. Special programming/wiring is required to use Ultra-Lift and Hoist Synchronization. Master: VFD is programmed for Ultra-Lift and requires an MFDI to be programmed for Sync 1.
Page 210: Troubleshooting Encoder Related Faults
6.2 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 211: Fault Code: Pgo-X-S/Pgo-X-H-Pulse Generator Signal Fault
8. If none of the above steps has identified a valid problem(s), only then should the speed deviation detection levels be adjusted. NOTE: The reaction time necessary to stop a load is limited to the lift of the hoist and the response time of the hoist brakes.
Page 212: Fault Code: Be1-Rollback Fault
6.2.3 Fault Code: BE1–Rollback Fault 6.2.3.1 Definition The BE1 fault indicates that the VFD has released the brake, but has not started to accelerate the motor when it detects more than the expected encoder feedback. A BE1 fault will occur if the pulses received during the BE1 detection time (C08-04) are greater than the expected number of pulses (C08-05).
Page 213: Fault Code: Be3-Brake Release Fault
5. If none of the above steps has identified a valid problem(s), the brake may need to be replaced. NOTE: It is desirable to have the Current Feedback Timer set as low as possible without causing nuisance trips. 6.2.5 Fault Code: BE3–Brake Release Fault 6.2.5.1 Definition The BE3 fault indicates that the VFD has released the brake and commanded the VFD to run, but has not detected...
Page 214: Alarm Code: Be6-Brake Proving Alarm
6.2.6 Alarm Code: BE6–Brake Proving Alarm 6.2.6.1 Definition The BE6 alarm indicates that the VFD 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 215: Alarm Code: Be8-Brake Slipping Alarm
6.2.7 Alarm Code: BE8–Brake Slipping Alarm 6.2.7.1 Definition The BE8 alarm indicates that the VFD has detected that the brake slipping after the brake is set. A BE8 alarm will occur if the VFD detects that the load is moving greater than the brake Slip Detection Speed (C08-23) when the brake is set.
Page 216: Fault Code: Oc-Over Current Fault
6.2.8 Fault Code: OC–Over Current Fault 6.2.8.1 Definition An over current fault is caused if the output current exceeds 200% of the VFD 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 217: Fault Display And Corrective Actions At Auto-Tuning
6.3 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 keypad displays that fault contents; the motor coasts to stop if it is under operation. Fault contact output or minor fault contact output does not operate.
Page 218 Fault Display Fault or Indicator Name/Description Corrective Action End 2 Motor Iron Core Saturation Coefficient Fault • Check the T1 parameters. (Rotation type tuning only). Since the motor iron • Check motor wiring. Saturation core saturation coefficient could not be auto-tuned •...
Page 219: Troubleshooting Option Card Related Faults
6.4 Troubleshooting Option Card Related Faults 6.4.1 VFD-Side Error Codes Table 6-6 on page 220 lists the various fault codes related to option cards. Check the following items first when an error code occurs on the VFD: • Communication cable connections. •...
Page 220 • Check if the VFD supports the AO-A3 Option Port CN5-A. installed into port CN5- option card to be installed. DI-A3 A is incompatible with Contact Magnetek for DO-A3 the VFD. assistance. • A PG option card is • PG option cards are supported S4IO...
Page 221 CN5-C. hardware is damaged. • If the problem continues, DI-A3 replace the control board or the oFC11 DO-A3 entire VFD. Contact Magnetek for instructions on replacing the S4IO control board. oFC12 A1-A3 Option Card Fault at Option Port • Option card or •...
Page 222: Copy Function Related Faults
6.5 Copy Function Related Faults 6.5.1 Tasks, Errors, and Troubleshooting The table below lists the messages and errors that may appear when using the Copy function. When executing the tasks offered by the Copy function, the keypad will indicate the task being performed. When an error occurs, a code appears on the keypad to indicate the error.
Page 223: Power Section Check
6.6 Power Section Check WARNING 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. It may take as long as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level.
Page 224 VOM (on RX1 Scale) Normal Reading (Analog Normal Reading Device Meter) (Digital Meter) Positive Lead Negative Lead 7–100 Ω Approximately 0.5 V Output Transistors Infinite Ω OL Displayed 10 Ω 0.5 V Infinite Ω OL Displayed Braking Diode Infinite Ω OL Displayed Infinite Ω...
Page 225: S4If Replacement Procedure
6.7 S4IF Replacement Procedure WARNING 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. It may take as long as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level.
Page 226 11. Complete all main circuit terminal connections as the installation of the S4IF interface card may block wiring access. NOTE: Wires to the S4IF interface card should be stripped 0.2" ±20% for maximum system safety. Solder dipping or ferrules are also highly recommended. 12.
Page 227 Appendix A: Parameter Listing Parameter Parameter Name Default Range Units Reference A01-01 Access Level 0–2 Page 56 A01-02 Control Method 0, 2, 3 Page 56 G+: 1 A01-03 Motion 0–2, 4 Page 57 VG+: 2 A01-04 Speed Reference 0–8 Page 57 A01-05 Init Parameters 0–8880...
Page 228 Parameter Parameter Name Default Range Units Reference B03-15 Ref Source 2 0–4 Page 76 B03-16 Run Source 2 0–3 Page 76 B03-21 PG Start Sel 0, 1 Page 76 B05-01 Accel Time 1 5.0* 0.0–25.5**** Page 77 B05-02 Decel Time 1 3.0* 0.0–25.5**** Page 77...
Page 229 Parameter Parameter Name Default Range Units Reference C03-11 Load Share Limit 0, 1 Page 86 C03-12 Klixon Action 0, 1 Page 87 C03-13 Height Measure 0–65535 Page 88 C03-14 Hook Height Home 0–4 Page 88 C03-15 Hook Height Out 0, 1 Page 88 C03-16 UL2 Revolutions...
Page 230 Parameter Parameter Name Default Range Units Reference SwiftLift REVSpd (V/f and OLV) C06-03 60.0 0.1–150.0 Page 96 UltraLift REVSpd (FLV) SL FWD Current (V/f) C06-04 SL FWD Torque (OLV) 0–100 Page 96 UL FWD Torque (FLV) SL REV Current (V/f) C06-05 SL REV Torque (OLV) 0–100...
Page 231 Parameter Parameter Name Default Range Units Reference C08-02 IFB OK Time 1.00 0.00–2.55 Page 104 C08-03 Min Brk Rel Trq 0–300 Page 104 C08-04 Rollback Timer 0.30 0.00–2.55 Page 104 C08-05 Rollback Count 0–15000 pulses Page 104 C08-06 BE3/Alt Torq Tim 0.30 0.00–2.55 Page 104...
Page 232 Parameter Parameter Name Default Range Units Reference C09-16 DIOTerminal 15 0–FF Page 108 C09-17 DIOTerminal 16 0–FF Page 108 C10-01 Load Weight 0–2 Page 109 C10-02 LW Start 0, 1 Page 109 C10-03 LW Display Hold 0, 1 Page 109 C10-04 LW Conversion 0–39999...
Page 233 Parameter Parameter Name Default Range Units Reference TRAV: 0–2 NLB: 2 C13-12 Index Brake Ctrl Page 117 NLB: 0, 2 else: 0 D01-01 DCInj Start Freq 0.0–10.0 Page 118 D01-02 DCInj Current 0–100 Page 118 D01-03 DCInj Time@Start 0.00 0.00–10.00 Page 118 D01-04 DCInj Time@Stop...
Page 234 Parameter Parameter Name Default Range Units Reference D08-04 Dwell Time @ Stop 0.0–10.0 Page 125 D09-01 SCrv Acc @ Start 0.20* 0.00–10.00 Page 126 D09-02 SCrv Acc @ End 0.20* 0.00–10.00 Page 126 D09-03 SCrv Dec @ Start 0.20* 0.00–10.00 Page 126 D09-04 SCrv Dec @ End...
Page 235 Parameter Parameter Name Default Range Units Reference E02-09*** Mechanical Loss 0.0–10.0 Page 135 E02-10*** Motor Iron Loss 0–65535 Page 135 E02-11 Rated Horsepower 0.00–650.00 Page 135 E03-02 Stopping Method 0, 1 Page 136 E03-03 Max Frequency 60.0 40.0–150.0 Page 136 230V: 0.0–255.0 E03-04 Max Voltage...
Page 236 Parameter Parameter Name Default Range Units Reference Traverse: 0–7 F01-26 PG Deviation Sel Page 138 NLB: 5 F01-27 PG Deviate Level 0–50 Page 138 F01-28 PG Deviate Time 0.0–10.0 Page 138 F02-01 AI Function Sel 0, 1 Page 139 F02-02 AI Input Gain 100.0 -999.9–999.9...
Page 237 Parameter Parameter Name Default Range Units Reference F06-56 DN Speed Scale -15–15 Page 144 F06-57 DN Current Scale -15–15 Page 144 F06-58 DN Torque Scale -15–15 Page 144 F06-59 DN Power Scale -15–15 Page 144 F06-60 DN Voltage Scale -15–15 Page 144 F06-61 DN Time Scale...
Page 238 Parameter Parameter Name Default Range Units Reference H01-09 F1 Key Selection 0F–74 Page 147 H01-10 F2 Key Selection 0F–74 Page 147 H01-14 Alt Ref Override 0, 1 Page 147 H02-01 Term M0-M1 Sel 0–1FF Page 151 H02-02 Term M2-M3 Sel 0–1FF Page 151 H02-03...
Page 239 Parameter Parameter Name Default Range Units Reference H05-12 Run CommandSel 0, 1 Page 164 H05-17 Busy Enter Sel 0, 1 Page 164 H05-18 MtrSpd Monitor T 0–100 Page 164 H06-01 Pulse Input Sel 0, 5–7 Page 165 H06-02 Pulse In Scale 1440 1000–32000 Page 165...
Page 240 Parameter Parameter Name Default Range Units Reference L04-05 Ref Loss Sel 0, 1 Page 170 L04-06 Fref at Floss 80.0 0.0–100.0 Page 170 L04-07 Freq Detect Sel 0, 1 Page 170 L05-01 Test Mode 0, 1 Page 171 L06-01 Torq Det 1 Sel 0–8 Page 171 L06-02...
Page 241 Parameter Parameter Name Default Range Units Reference O01-03 Display Scaling A01-02 0–3 Page 182 O01-04 Display Units A01-02 0, 1 Page 182 O01-05 LCD Contrast 0–5 Page 182 O01-10 UserDisp Scaling 6000 1–60000 Page 182 O01-11 UserDisp Dec Sel 0–3 Page 182 O02-01 LO/RE Key...
Page 242 Parameter Parameter Name Default Range Units Reference U01-05 Motor Speed Page 189 U01-06 Output Voltage Page 189 U01-07 DC Bus Voltage Page 189 U01-08 Output Power HP/kW Page 189 U01-09 Torque Reference Page 189 U01-10 Input Term Sts Page 189 U01-11 Output Term Sts Page 189...
Page 243 Parameter Parameter Name Default Range Units Reference U02-02 Last Fault Page 192 U02-03 Frequency Ref Page 192 U02-04 Output Freq Page 192 U02-05 Output Current Page 192 U02-06 Motor Speed Page 192 U02-07 Output Voltage Page 192 U02-08 DC Bus Voltage Page 192 U02-09 Output Power...
Page 244 Parameter Parameter Name Default Range Units Reference U04-01 Drv Elapsed Time Page 194 U04-03 Fan Elapsed Time Page 194 U04-04 Fan Life Mon Page 194 U04-05 Cap Life Mon Page 194 U04-06 ChgCirc Life Mon Page 194 U04-07 IGBT Life Mon Page 194 U04-08 Heatsink Temp...
Page 245 Verify the following installation conditions to ensure that other devices and machinery used in combination with this VFD also comply with EMC guidelines. 1. Install an EMC noise filter to the input side specified by Magnetek for compliance with European standards. 2. Place the VFD and EMC noise filter in the same enclosure.
Page 246 Figure B-2: Installation Method 5. Make sure the protective earthing conductor complies with technical standards and local safety regulations. WARNING Electrical Shock Hazard. Because the leakage current exceeds 3.5 mA in models 4370 to 41090-G+/VG+S4, IEC 61800-5-1 states that either the power supply must be automatically disconnected in case of discontinuity of the protective earthing conductor, or a protective earthing conductor with a cross-section of at least 10 mm (Cu) or 16 mm (Al) must be used.
Page 247 Figure B-4: EMC Filter and VFD Installation for CE Compliance ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 247...
Page 248 EMC Filters Install the VFD with the EMC filters listed in Table B-1 through Table B-4 to comply with the EN61800-3 requirements. Schaffner filters are supplied in North America, and Block filters are supplied in Europe. Table B-1: IEC/EN61800-3 Filters (Manufacturer: Schaffner) – 230 V Class Filter Data (Manufacturer: Schaffner) Mounting Rated...
Page 249 Table B-2: IEC/EN61800-3 Filters (Manufacturer: Schaffner) – 460 V Class Filter Data (Manufacturer: Schaffner) Mounting Rated Dimensions VFD Model Weight Dimensions Current Schaffner Type Figure W x D x H (in) Y x X (in) lb (kg) [W x D x H (mm)] [Y x X (mm)] 4001 4003...
Page 250 Figure B-6 Figure B-5 Figure B-7 ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 250...
Page 251 Table B-3: EN 61800-3 Filters (Manufacturer: Block) – 230 V Class Filter Data (Manufacturer: Block) Mounting Rated Dimensions VFD Model Weight Dimensions Current Block Type Figure W x D x H (in) Y x X (in) lb (kg) [W x D x H (mm)] [Y x X (mm)] 2003 5.5 x 2 x 11.9...
Page 252 Table B-4: EN 61800-3 Filters (Manufacturer: Block) – 460 V Class Filter Data (Manufacturer: Block) Mounting Rated Dimensions VFD Model Weight Dimensions Current Block Type Figure W x D x H (in) Y x X (in) lb (kg) [W x D x H (mm)] [Y x X (mm)] 4001 4003...
Page 253 Figure B-9 Figure B-8 Figure B-10 Figure B-11 ® IMPULSE •G+ & VG+ Series 4 Technical Manual November 2020 Page 253...
Page 254 DC Link Chokes for EN 61000-3-2 Compliance Table B-5: DC Link Chokes for Harmonic Reduction DC Link Chokes VFD Model Rating 2003 5.4 A, 8 mH 2005 4001 3.2 A, 28 mH 4003 NOTE: DC link chokes are not required for other models to comply with EMC. ®...
Page 255 Manufacturer’s Address N49W13650 Campbell Drive Menomonee Falls, WI 53051 The undersigned hereby declares on behalf of Magnetek, that the above-referenced product, to which this declaration relates, is in conformity with the provisions of the following directives: • Low Voltage Directive (2014/35/EU) •...
Page 256 ® IMPULSE •G+ & VG+ Series 4 Adjustable Frequency/Vector Crane Controls Technical Manual November 2020...

This manual is also suitable for:

Impulse vg+ 4 series

Magnetek IMPULSE G+ 4 Series Technical Manual

Quick Links

Troubleshooting

Related Manuals for Magnetek IMPULSE G+ 4 Series

Summary of Contents for Magnetek IMPULSE G+ 4 Series

This manual is also suitable for:

Table of Contents