Page 2 This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of the Columbus McKinnon Corporation. Parts of this product may be covered by one or more of the following patents: 7,190,146, 7,841,583, 8,401,814, 8,669,724, 8,686,670, and 3,017,333 (Canada).
Page 3 PRODUCT SAFETY INFORMATION ® Magnetek offers a broad range of radio remote control products, control products and variable frequency drives (VFD), and industrial braking systems for material handling applications. This manual has been prepared by Magnetek to provide information and recommendations for the installation, use, operation and service of Magnetek’s material handling products and systems (Magnetek Products).
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 ............................... 9 How to Use This Manual......................... 10 General Information ..........................11 1.2.1 Assessing the System Requirements....................11 1.2.2 Assessing the VFD Environment......................11 Specifications............................12 1.3.1 VFD Specifications ..........................12 1.3.2 AC Reactor Specifications........................15 1.3.3 Terminal Board Specifications......................
Page 6 Auto-Tuning ............................75 4.4.1 Rotational Auto-Tune (T01-01 = 0) ....................76 4.4.2 Non-Rotational Auto-Tune 1 (T01-01 = 1)..................76 4.4.3 Non-Rotational Terminal Resistance Auto-Tune (T01-01 = 2) ............77 Programming Advanced Features........................78 Application Parameters........................... 78 5.1.1 Frequency References ........................78 5.1.2 Reference Limits ..........................
Page 7 5.3.8 Duty & Carrier Frequency......................... 146 Motor Parameters ..........................147 5.4.1 Voltage/Frequency (V/f) Pattern for Motor 1 ..................147 5.4.2 Motor 1 Parameters.......................... 154 5.4.3 Voltage/Frequency (V/f) Pattern for Motor 2 ..................156 5.4.4 Motor 2 Parameters.......................... 157 5.4.5 Test Mode ............................157 Option Card Parameters ........................
Page 8 Terminal Board (24 VDC) Replacement Procedure................249 Appendix A: Parameter Listing ..........................250 Appendix B: Standards Compliance ........................279 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 8...
Page 9: 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 10: How To Use This Manual
1.1 How to Use This Manual ® This manual provides technical information on IMPULSE •G+/VG+ Series 5 VFD (variable frequency drive) parameter settings, functions, troubleshooting, and installation details. Use this manual to expand the functionality and to take advantage of higher performance features. This manual is available for download at www.cmco.com/magnetek.
Page 11: General Information
1.2 General Information 1.2.1 Assessing the System Requirements It is important to know how the VFD will be utilized before installation. Please know the requirements for the following components: • Speed control method(s) - i.e. stepped, stepless, infinitely variable • Braking method(s) - coast to stop, decel to stop, NLB Hoist •...
Page 12: Specifications
1.3 Specifications 1.3.1 VFD Specifications Table 1-2: VFD Capacity - Heavy Duty 230 VAC 460 VAC 575 VAC Output Input Output Input Output Input Model Model Model Current Power Current Power Current Power (G+/VG+ S5) (G+/VG+ S5) (G+/VG+ S5) (kVA) (kVA) (kVA) 2003...
Page 13 Table 1-3: VFD Specifications Specification Specification Value and Information for All Models Global Certifications UL, CSA, CE (with filters), RCM, RoHs Crane Duty Classification CMAA Crane Duty Class A - F (or equivalent) 230 VAC Class: • AC: 200 to 240 VAC, 3-phase, 50/60 Hz •...
Page 14 Specification Specification Value and Information for All Models 230 VAC Class: Stops when DC bus voltage falls below approx. 190 VDC Undervoltage protection level 460 VAC Class: Stops when DC bus voltage falls below approx. 380 VDC 575 VAC Class: Stops when DC bus voltage falls below approx. 475 VDC Heatsink overtemperature Thermostat trips at approximately 100°C (212°F) Torque limit selection...
Page 15: Ac Reactor Specifications
1.3.2 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 are recommendations to help determine input and output reactor requirements: •...
Page 16 Table 1-5: 460 V Class VFD Model Number Reactor Part Number Reactor Fundamental Amps Reactor HP (kW) 4001-G+/VG+S5 REA460-1 1 (0.75) 4003-G+/VG+S5 REA460-2 2 (1.5) 4004-G+/VG+S5 REA460-3 3 (2.2) 4005-G+/VG+S5 REA460-5 5 (3.7) 4007-G+/VG+S5 REA460-5 5 (3.7) 4009-G+/VG+S5 REA460-5 5 (3.7) 4014-G+/VG+S5 REA460-7.5 7.5 (5.6)
Page 17: Terminal Board Specifications
1.3.3 Terminal Board Specifications IMPULSE•G+/VG+ Series 5 is designed to interface with user input and output devices through the integrated terminal board. This eliminates the need for an additional interface relay or isolation circuitry. The terminal board supports 24VDC digital inputs. The terminal board has eight optically isolated input terminals which can be used to connect the user input device to the VFD.
Page 18: Installation
2 Installation WARNING • When preparing to mount the IMPULSE•G+/VG+ Series 5 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 19: System Components
2.2 System Components 2.2.1 Standard Components • Terminal Board (24VDC with Optional 120VAC Interface Card) • PG-X3 Line Driver Encoder Option Card (VG+ only) 2.2.2 Optional Components • DI-A3 Digital DC Input Option Card • DO-A3 Digital Output Option Card •...
Page 20: Long-Term Storage And Capacitor Reforming
2.3 Long-Term Storage and Capacitor Reforming Powering up the VFD every six months is recommended. Over longer periods of time without power, the VFD’s electrolytic DC bus capacitors require reformation, especially if stored in an area of high temperatures. Capacitor reforming is required if VFDs are stored without power for more than 2 to 3 years.
Page 21 Figure 2-1: Capacitor Reform Diagrams IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 21...
Page 22: Installation Orientation
2.4 Installation Orientation Figure 2-2: Standard Installation Orientation 2.5 Recommended Installation 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 23: Optional Side-By-Side Installation
2.6 Optional Side-by-Side Installation Models 2003 to 2075 and 4001 to 4039 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. Figure 2-4: Side-by-Side Installation IMPULSE•G+/VG+ Series 5 Technical Manual August 2023...
Page 24: Vfd Derating
2.7 VFD Derating 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 25: Dimensions (Open-Chassis)
2.8 Dimensions (Open-Chassis) Figure 2-6 Figure 2-7 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 25...
Page 26 Figure 2-8 Figure 2-9 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 26...
Page 27 Figure 2-10 Figure 2-11 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 27...
Page 28 Figure 2-12 Figure 2-13 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 28...
Page 29 Figure 2-14 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 29...
Page 30 Table 2-1: Open-Chassis Dimensions – 230 V Class Dimensions - inches (mm) Heat Weight Model Figure Loss lbs (kg) (W)* 2003 5.51 (140) 10.24 (260) 6.93 (176) 4.02 (102) 4.02 (102) 9.76 (248) 7.7 (3.5) 2005 5.51 (140) 10.24 (260) 6.93 (176) 4.02 (102) 4.02 (102)
Page 31 Table 2-2: Open-Chassis Dimensions – 460 V Class Dimensions - inches (mm) Heat Weight Model Figure Loss lbs (kg) (W)* 4001 5.51 (140) 10.24 (260) 6.93 (176) 4.02 (102) 4.02 (102) 9.76 (248) 7.5 (3.4) 4003 5.51 (140) 10.24 (260) 6.93 (176) 4.02 (102) 4.02 (102)
Page 32: 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 33 • 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 = 1 or swap the A+ and A- wires).
Page 34 Figure 3-1: Typical Connection Diagram IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 34...
Page 35: 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 VFD. These devices can be thermal, magnetic, or molded-case circuit breakers (MCCB);...
Page 36 Table 3-2: Wire Size and Circuit Protection for 460 V Class Recommended Maximum Circuit Protection Recommended Wire Size (AWG) Model Number Ground Ground Time Delay Time Delay Continuous Control (G+/VG+ S5) Inverse Time Circuit Copper Copper HD Input Input Fuse Input Fuse Power Circuit Wiring Breaker (A)
Page 37 Table 3-3: Wire Size Range and Tightening Torque for 230 V Class Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 14 - 6 1.5 - 1.7 R/L1, S/L2, T/L3 (2.5 - 16) (13.5 - 15) 14 - 6 1.5 - 1.7 U/T1, V/T2, W/T3 (2.5 - 16)
Page 38 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 14 - 6 1.5 - 1.7 R/L1, S/L2, T/L3 (2.5 - 16) (13.5 - 15) 14 - 6 1.5 - 1.7 U/T1, V/T2, W/T3 (2.5 - 16) (13.5 - 15) 14 - 3 2.3 - 2.5 2011...
Page 39 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 14 - 6 1.5 - 1.7 R/L1, S/L2, T/L3 (2.5 - 16) (13.5 - 15) 14 - 6 1.5 - 1.7 U/T1, V/T2, W/T3 (2.5 - 16) (13.5 - 15) 14 - 3 2.3 - 2.5 2033...
Page 40 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 6 - 1/0 8 - 9 R/L1, S/L2, T/L3 (16 - 50) (71 - 80) 6 - 1/0 8 - 9 U/T1, V/T2, W/T3 (16 - 50) (71 - 80) 2 - 2/0 10 - 12 2088...
Page 41 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 3 - 4/0 x 2P R/L1, S/L2, T/L3 (25 - 95 x 2P) (177) 3 - 4/0 x 2P U/T1, V/T2, W/T3 (25 - 95 x 2P) (177) 2 - 250 x 2P 2215 -, +1 (35 - 120 x 2P)
Page 42 Table 3-4: Wire Size Range and Tightening Torque for 460 V Class Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 14 - 6 1.5 - 1.7 R/L1, S/L2, T/L3 (2.5 - 16) (13.5 - 15) 14 - 6 1.5 - 1.7 U/T1, V/T2, W/T3 (2.5 - 16)
Page 43 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 14 - 6 1.5 - 1.7 R/L1, S/L2, T/L3 (2.5 - 16) (13.5 - 15) 14 - 6 1.5 - 1.7 U/T1, V/T2, W/T3 (2.5 - 16) (13.5 - 15) 14 - 3 2.3 - 2.5 4007...
Page 44 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 2.3 - 2.5 14 - 3 R/L1, S/L2, T/L3 (2.5 - 25) (19.8 - 22) 2.3 - 2.5 14 - 4 U/T1, V/T2, W/T3 (2.5 - 25) (19.8 - 22) 14 - 1 5 - 5.5 4024...
Page 45 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 2.3 - 2.5 14 - 3 R/L1, S/L2, T/L3 (2.5 - 25) (19.8 - 22) 2.3 - 2.5 14 - 3 U/T1, V/T2, W/T3 (2.5 - 25) (19.8 - 22) 2.3 - 2.5 14 - 2 4060...
Page 46 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 2 - 250 12 - 14 R/L1, S/L2, T/L3 (35 - 120) (107 - 124) 2 - 300 12 - 14 U/T1, V/T2, W/T3 (35 - 150) (107 - 124) 6 - 2/0 8 - 9 4150...
Page 47 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 2/0 - 300 x 2P R/L1, S/L2, T/L3 (70 - 150 x 2P) (310) 2/0 - 300 x 2P U/T1, V/T2, W/T3 (70 - 150 x 2P) (310) 4/0 - 400 x 2P 4304 -, +1 (95 - 185 x 2P)
Page 48 Wire Range AWG Model Terminal Screw Size Tightening Torque N·m (lbf-in) 2/0 - 300 x 4P R/L1, S/L2, T/L3 (70 - 150 x 4P) (310) 2/0 - 300 x 4P U/T1, V/T2, W/T3 (70 - 150 x 4P) (310) 3/0 - 400 x 4P 4515 -, +1 (95 - 185 x 4P)
Page 49: Power Circuit Wiring
3.3 Power Circuit Wiring To wire the power circuit for IMPULSE•G+/VG+ Series 5: 1. Run the power supply wires through an appropriate enclosure hole. 2. Connect the power supply wires to a circuit protection system. See Section 3.2 on page 35. 3.
Page 50: Power Circuit Connection Diagrams
3.3.1 Power Circuit Connection Diagrams Figure 3-2: Power Circuit Connections (2003 to 2075, 4001 to 4039) Figure 3-3: Power Circuit Connections (2088 and 2115, 4045 and 4150) IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 50...
Page 51 Figure 3-4: Power Circuit Connections (2145 to 2415, 4180 to 4371) Figure 3-5: Power Circuit Connections (4414 to 4605) IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 51...
Page 52: Power Circuit Terminal Block Diagrams
3.3.2 Power Circuit Terminal Block Diagrams Figure 3-6 through Figure 3-19 show the main circuit terminal arrangements for the various VFD models. Figure 3-6: Main Circuit Terminal Block Figure 3-10: Main Circuit Terminal Block (4045) (2003 - 2033, 4001 - 4018) Figure 3-7: Main Circuit Terminal Block (2047, Figure 3-11: Main Circuit Terminal Block (2088) 4024, 4031)
Page 53 Figure 3-14: Main Circuit Terminal Block (4075) Figure 3-17: Main Circuit Terminal Block (2215, 2283, 4180 - 4260) Figure 3-15: Main Circuit Terminal Block (2145, 2180) Figure 3-18: Main Circuit Terminal Block (2346, 2415, 4304, 4371) Figure 3-16: Main Circuit Terminal Block (4112, 4150) Figure 3-19: Main Circuit Terminal Block (4414 - 4605)
Page 54: Grounding
3.4 Grounding Connect the VFD’s ground terminal to a common grounding point on the control panel. Use ground wiring as specified in Section 3.2 on page 35, and keep the length as short as possible. • Ground Resistance: • For 230V class: 100Ω or less •...
Page 55: Terminal Board (24 Vdc) & Interface Card (120 Vac)
3.5 Terminal Board (24 VDC) & Interface Card (120 VAC) Table 3-6: Terminal and Wire Specifications Tightening Torque Wire Size Circuit Board Screw Size lbf·in (N·m) AWG (mm 24 VDC Terminal Board 4.4 to 5.3 Single Stranded: 24 to 17 (0.25 to 1.0) (0.5 to 0.6) Single Solid: 24 to 16 (0.25 to 1.5) 120 VAC Interface Card...
Page 56: Dip Switch And Jumper Functions
3.5.2 DIP Switch and Jumper Functions DIP Switches and Jumpers are described in this section, and the functions are shown in Table 3-7 Table 3-7: DIP Switches Name Function Setting S1-1 Analog Input A1 Signal V: 0–10VDC or -10–10VDC (internal impedance: 20 kΩ) (default) Level I: 0–20mA or 4–20mA (internal impedance: 250 Ω) S1-2...
Page 57 Type Terminal Function Description Signal Level Analog Inputs MFAI Power Supply Analog input positive supply +10.5 VDC, 20 mA MFAI Power Supply Analog input negative supply -10.5 VDC, 20 mA MFAI 1 Multi-function analog input 1 -10 to 10 VDC (impedance: 20kΩ) (H03-02) 0 to 10 VDC (impedance: 20kΩ) 0 to 20 mA (impedance: 250kΩ)
Page 58: Control Circuit Terminal Block Diagrams
3.6.1 Control Circuit Terminal Block Diagrams Figure 3-24: Terminal Board Diagram 3.6.2 Sinking/Sourcing for Digital Inputs (24 VDC Only) Use the wire jumper between terminals SC and SP or SC and SN to select Sink mode, Source mode, or to externally power the digital inputs.
Page 59: Safe Disable And Safe Torque Off
3.6.3 Safe Disable and 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 PL e, IEC/EN 61508 (SIL3), and IEC/EN 62061 (SIL CL3).
Page 60: Encoder Circuit
3.7 Encoder Circuit A shaft-mounted encoder is required to provide speed and shaft position feedback to the IMPULSE•VG+ Series 5. Without an encoder, closed loop vector control cannot operate properly. Before you wire the encoder circuit, refer to Table 3-10 on page 60 and Table 3-11 on page 61. 3.7.1 Encoder Circuit Specification and Wiring Procedure Table 3-10: Encoder and PG-X3 Option Card Specifications Power supply...
Page 61: Encoder Wiring Diagram
3.7.2 Encoder Wiring Diagram Encoder 1: Install in option port CN5-C Encoder 2: Install in option port CN5-B Figure 3-26: PG-X3 Encoder Card Wiring Table 3-11: Encoder Wiring Encoder Signal Wire Color Example PG-X3 Terminal +5 or 12 VDC (select via CN3 jumper) Black Blue Gray...
Page 62: Getting Started
4 Getting Started 4.1 Overview With its easy-to-use keypad and X-Press Programming, the IMPULSE•G+/VG+ Series 5 makes it easy to get up and running quickly. In addition to explaining the keypad and X-Press Programming, this chapter explains how to navigate the menus and configure the VFD. 4.1.1 Checks Before Powering After VFD installation and wiring are completed, verify: •...
Page 63: Keypad Led And Button Functions
4.2.1 Keypad LED and Button Functions Lit while VFD is operating the motor; Flashing during a phantom fault. Off during normal operation (no fault or alarm). Lit during a fault; Flashing during an alarm, oPE, or error. Memory Card Slot No function.
Page 64: Parameters
4.3 Parameters There are a variety of parameters that determine how the VFD functions. These parameters are programmed into the VFD’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 65: Menu Structure
4.3.2 Menu Structure Figure 4-1: Menu Structure IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 65...
Page 66 Group Function Operation Status Fault Trace Monitor Fault History Maintenance Additional Operation Status Initial Setup Initialize User Parameters Frequency References Reference Limits Operation Mode Application Acceleration/Deceleration Times Jump Frequencies Field Forcing Quick Stop Reverse Plug Simulation Micro-Speed End of Travel Limits Phantom Stop Hook Height Measurement Electronic Programmable Limit Switches (EPLS)
Page 67: Initial Setup
4.3.3 Initial Setup 4.3.3.1 Parameter Access Level (A01-01) This parameter allows the “masking” of parameters according to user level. 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. Advanced Level Commonly used parameters can be viewed and edited.
Page 68 4.3.3.3 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 70, Table 4-7 on page 71, and Table 4-8 on page 72 for X-Press Programming™...
Page 69 Table 4-5: X-Press Programming I/O Quick Reference A01-04 = Terminal S1 Terminal S2 Terminal S3 Step 2 Step 2 Step 2 Accel Hold Terminal S4 Step 3 Step 3 Accel Terminal S5 Step 4 Terminal S6 Step 5 Terminal S7 Terminal S8 Terminal A1 FREF...
Page 70 4.3.3.6 Parameters Changed by X-Press Programming Table 4-6: Traverse (A01-03 = 0) A01-04 = Parameter Description 2-Speed 3-Speed 5-Speed 2-Step 3-Step Uni-Polar Bi-Polar Multi- Multi- Multi- Infinitely Infinitely Analog Analog Step Step Step Variable Variable b01-01 Speed 1 20.00 15.00 6.00 15.00 15.00...
Page 71 Table 4-7: Standard Hoist (A01-03 = 1) A01-04 = Parameter Description 2-Speed 3-Speed 5-Speed 2-Step 3-Step Uni-Polar Bi-Polar Multi- Multi- Multi- Infinitely Infinitely Analog Analog Step Step Step Variable Variable b01-01 Speed 1 20.00 15.00 6.00 15.00 15.00 15.00 15.00 b01-02 Speed 2 60.00...
Page 72 Table 4-8: NLB Hoist (A01-03 = 2) A01-04 = Parameter Description 2-Speed 3-Speed 5-Speed 2-Step 3-Step Uni-Polar Bi-Polar Multi- Multi- Multi- Infinitely Infinitely Analog Analog Step Step Step Variable Variable b01-01 Speed 1 20.00 15.00 6.00 15.00 15.00 15.00 15.00 b01-02 Speed 2 60.00...
Page 73 4.3.3.7 Initialize Parameters (A01-05) Use this parameter to reset the VFD to its factory default settings or transfer parameters. Table 4-9: Initialize Settings Setting Description No Initialization (factory default) 1110 User Default 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 74 4.3.3.10 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 75: Auto-Tuning
4.4 Auto-Tuning CAUTION The brake output is not energized during Auto-Tune. The brake must be manually released before a rotational Auto-Tune and reengaged when Auto-Tuning is complete. Ensure no load is on the hook, and that the hook is near the floor. The IMPULSE•G+/VG+ Series 5 can perform a calibration process with its automatic tuning function.
Page 76: Rotational Auto-Tune (T01-01 = 0)
4.4.1 Rotational Auto-Tune (T01-01 = 0) This is a rotational Auto-Tuning method for Open Loop Vector and Closed Loop Vector only, which allows for Auto- Tuning a motor that is unloaded and ideally decoupled from the gearbox. The brake must also be disengaged. The instructions below will provide a step-by-step procedure to complete this Auto-Tune function: 1.
Page 77: Non-Rotational Terminal Resistance Auto-Tune (T01-01 = 2)
4.4.3 Non-Rotational Terminal Resistance Auto-Tune (T01-01 = 2) This is a non-rotational Auto-Tuning method, which allows for Auto-Tuning without decoupling the motor. This method is recommended for motors configured with the V/f control method when the motor horsepower and motor rated current are known. The instructions below will provide a step-by-step procedure to complete this Auto-Tune function: 1.
Page 78: Programming Advanced Features
5 Programming Advanced Features 5.1 Application Parameters The application parameters control the speed references, acceleration and deceleration characteristics, and reference sources. Application parameters included in this section are listed below: • b01 Frequency References • b02 Reference Limits • b03 Operation Mode •...
Page 79 Table 5-2: Multi-Step Speed Processing by Multi-Function Digital Input (b01-01–b01-16) Forward/ Multi-Step Multi-Step Multi-Step Multi-Step Jog/Inch Speed Reverse Speed 2 Speed 3 Speed 4 Speed 5 H01-XX = 15, 16, Reference Terminal S1 H01-XX = 0 H01-XX = 1 H01-XX = 2 H01-XX = 3 17, 18 or S2...
Page 80: 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 81: Operation Mode
5.1.3 Operation Mode Determines the source from where the frequency reference and RUN command are generated. Table 5-4: Run/Reference Source Parameter Settings Parameter Display Function Range Default b03-01 Frequency Reference Source from where the frequency reference is 0–5 Selection 1 generated.
Page 82: Stopping Method
5.1.4 Stopping Method Selects the stopping method suitable for the application. Table 5-5: Stopping Method Parameter Settings Parameter Display Function Range Default b03-03 Stopping Method Selection Determines the stopping method. 0, 1, 4, 6 G+: 0* VG+: 6* 0 Decel to Stop (Figure 5-2) 1 Coast to Stop (Figure 5-3)
Page 83 5.1.4.2 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 5.1.4.3 Decel with Timer (b03-03 = 4) NOTE: This option is only available in traverse motion. Upon run command removal, the motor decelerates to stop.
Page 84: Motor Rotation Change
5.1.5 Motor Rotation Change This parameter allows you to change the motor direction without changing the motor leads. Table 5-6: Motor Rotation Change Parameter Settings Parameter Display Function Range Default b03-04 Phase Order Selection Motor phase order 0, 1 0 Standard 1 Switch Phase Order Reverses the motor direction NOTE: To reverse the direction of rotation, set b03-04 = 1, or swap any two motor leads (changing R/L1, S/L2, or...
Page 85: Run Select
5.1.7 Run Select Determines additional RUN command options and the secondary source from where the frequency reference and RUN command are generated. Table 5-8: Run Select Parameter Settings Parameter Display Function Range Default b03-08 Run Command Select in Determines whether the VFD is allowed to run 0–2 PRG Mode while inside the Programming menu.
Page 86 Figure 5-5: Digital Input Deadband Time (b03-35) IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 86...
Page 87: Acceleration/Deceleration Time
5.1.8 Acceleration/Deceleration Time 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 5-9: Acceleration/Deceleration Time Parameter Settings Parameter Display...
Page 88: Accel/Decel Time Switching Frequency
5.1.9 Accel/Decel Time Switching Frequency Accel/Decel times can be changed automatically without using digital inputs. Alternatively, digital inputs can be used to enable additional accel and decel times. This has priority over automatic change of Accel/Decel. Table 5-10: Accel/Decel Time Switching Frequency Parameter Settings Parameter Display Function...
Page 89: Jump Frequencies
5.1.10 Jump Frequencies Allows the “jumping” of critical frequencies so that the motor can operate without resonant vibrations caused by some machine systems. This is also used for deadband control. A setting of 0.0 Hz disables this function. Table 5-11: Jump Frequencies Parameter Settings Parameter Display Function...
Page 90: Offset Frequencies
5.1.11 Offset Frequencies This function consists of three digital inputs to add or subtract an offset to/from the frequency reference and correct the speed. Each offset input is applied as a percentage of the Maximum Output Frequency (E01-04). When more than one offset is enabled at the same time, the offsets are added together.
Page 91: Crane & Hoist Functions
5.2 Crane & Hoist Functions Table 5-14: Crane & Hoist Function Availability Access Level (A01-01) Advanced (2) or Expert (3) Motion (A01-02) Traverse (0) Standard Hoist (1) Hoist (2) Function/Control Method (A01-03) V/f (0) OLV (2) CLV (3) V/f (0) OLV (2) CLV (3) C01: Quick Stop...
Page 92: Quick Stop
5.2.1 Quick Stop Quick Stop 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 93: Reverse Plug Simulation
5.2.2 Reverse Plug Simulation 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 Standard Hoist mode (A01-03 = 1). Table 5-16: Reverse Plug Simulation Parameter Settings Parameter Display...
Page 94: 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 and can be adjusted and enabled independently. Table 5-17: Micro-Speed Parameter Settings Parameter Display Function...
Page 95: 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. Travel limit inputs can be programmed through the H01 and F03 digital input parameters.
Page 96: Phantom Stop
5.2.5 Phantom Stop Phantom Stop allows quick identification of a faulted VFD while stopping other VFDs with Phantom Stop enabled. This feature is designed to stop the VFD operation using the stopping method selected in C03-10 when a Phantom Fault input (H01-xx = 5F or 15F) is active. The VFD will indicate a Phantom Fault by blinking the keypad RUN key LED, in sequence of two short bursts.
Page 97: Electronic Programmable Limit Switches (Epls)
Table 5-21: Monitor Values at Hook Height Home Position C03-16 = 0 C03-16 = 1 C03-15 U01-51 U01-50 U01-50 100% C03-13 100% 100% C03-13 100% 100% 5.2.7 Electronic Programmable Limit Switches (EPLS) Using the motor revolutions (U01-51) from the Hook Height Measurement function, it is possible to program UL0, UL1, UL2, UL3, LL0, LL1, LL2, and LL3 positions without the use of rotary limit switches.
Page 98 Table 5-23: Limit Switch Outputs H02-0x or F05-0x = Function 2B - Upper Limit 1 Output ON when keypad displays UL1 2C - Upper Limit 2 Output ON when keypad displays UL2 2D - Lower Limit 1 Output ON when keypad displays LL1 2E - Lower Limit 2 Output ON when keypad displays LL2 2F - Upper/Lower Limit 3...
Page 99: Upper/Lower Limit Bypass
5.2.8 Upper/Lower Limit Bypass The Limit Bypass allows for the following without the use of jumpers or re-programming parameters: 1. Ease of testing the Weighted Upper Limit Switch (UL3) or re-homing the Hook Height. 2. To allow changing of the wire ropes, i.e. spooling all the rope off of the hoist drum. NOTE: A momentary key-switch is recommended to operate this function and should only be accessible to maintenance personnel, not the crane operator.
Page 100 Figure 5-13: Upper Limits (UL1 / UL2) Figure 5-14: Lower Limits (LL1 / LL2) IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 100...
Page 101: Analog Input Programmable Limits
5.2.9 Analog Input Programmable Limits The Analog Input Programmable Limits function allows for a LaserGuard 2 laser to be connected to an analog input of the VFD. This function will assign travel limits based on the analog input signal. Table 5-25: Analog Input Programmable Limits Parameters Parameter Display Function...
Page 102: Hook Height Set Points
5.2.10 Hook Height Set Points The Hook Height Set Points function provides an indication of the hook height position using a configurable action of an analog output. Table 5-26: Hook Height Set Points Parameters Parameter Display Function Range Default C03-60 Hook Height Point 1 Determines when the digital output (MFDO = 0–2...
Page 103: Load Share (Torque Following)
5.2.12 Load Share (Torque Following) Load Share allows one or more mechanically coupled motors to be connected in a Leader/Follower fashion where the Follower VFD will follow the torque reference of the Leader VFD. It can be configured in two ways, either as a dedicated Follower or as a Leader/Follower that can be switched with a digital input.
Page 104: Load Check
5.2.13 Load Check The Load Check function is a load-limiting feature which ensures the programmed load limit of the hoist is not exceeded. It prevents the lifting (and potential stall) of a load that is overweight. When an overload condition is detected, further lifting is restricted.
Page 105 4. Motor should be at normal operating temperature for the application (operate at or near rated capacity for at least 10 minutes) before performing the Load Check set up process. 5. Suspend the rated load just off of the ground (this allows for accurate measurements during calibration). 6.
Page 106 Parameter Display Function Range Default C05-07 Detection Margin at Margin for Load Check detection at speed 0–50% Speed Agree agree. A setting of 0 is the most sensitive. C05-08 Alarm Speed Maximum lowering speed after an LC alarm. 0.0–30.0 Hz C05-09 Load Check Level 01 Current/Torque for Zone 01...
Page 107: Ultra-Lift
5.2.14 Ultra-Lift Ultra-Lift provides additional productivity by allowing a hoist to run above base speed when the load is less than 100% of the rated capacity. Ultra-Lift determines the torque required for the load, calculates the maximum safe speed, and automatically accelerates to this speed. The maximum speed cannot exceed the lesser value of the Maximum Forward Speed (C06-02), Maximum Reverse Speed (C06-03), and Maximum Frequency (E01-04).
Page 108 Parameter Display Function Range Default C06-06 Ultra-Lift Enabling Speed Frequency at which to trigger Ultra-Lift. 0.1–300.0 Hz 59.0 C06-07 Ultra-Lift Delay Time Delay time at Enabling Speed to check Output 0.0–25.5 sec Current/Torque C06-08 Ultra-Lift Accel Multiplier Acceleration multiplier for V/f Modes. Greater 0.1–9.9 than 1 increases accel time;...
Page 109: Torque Limit
5.2.15 Torque Limit IMPULSE•G+/VG+ Series 5 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. • Forward Motoring (I) •...
Page 110 Table 5-31: Torque Limit Parameter Settings Parameter Display Function Range Default C07-01 Forward Torque Limit Forward Motoring torque limit 0–300% C07-02 Reverse Torque Limit Reverse Motoring torque limit 0–300% C07-03 Forward Regenerative Forward Regenerative torque limit 0–300% Torque Limit C07-04 Reverse Regenerative Reverse Regenerative torque limit 0–300%...
Page 111: Anti-Shock
5.2.16 Anti-Shock Anti-Shock is a hoist feature on the IMPULSE•VG+ Series 5 VFD. 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). Anti-Shock is designed to reduce crane structure fatigue.
Page 112 Table 5-32: Anti-Shock Parameter Settings Parameter Display Function Range Default C07-12 Anti-Shock Enables or disables the Anti-Shock function. 0–2 0 Disabled Anti-Shock is disabled. 1 Enabled Anti-Shock is enabled always. 2 Enabled, Not in Micro- Disables Anti-Shock if Micro-Speed is Speed enabled.
Page 113: Torque Time Filter
5.2.17 Torque Time Filter The Torque Time Filter function assigns a time filter to allow the torque to build at start. Table 5-33: Torque Time Filter Parameter Settings Parameter Display Function Range Default C07-30 Torque Limit Process at Adds a 64ms ramp-up time to the torque limits at the 0, 1 Start start of a run.
Page 114 Stop The stop sequence begins when the run command has been removed and the output frequency has decelerated to zero. Once at zero speed, the motor maintains a Load Float position for the duration of C08-10 (Load Float Time). During the Load Float time, run commands in either direction are accepted and will begin accelerating immediately in the commanded direction, thereby skipping the start sequence.
Page 115 If a brake fault is annunciated after the hoist has come to a complete stop, and Load Float (C08-10) has timed out, it would indicate that the VFD has checked the brake and determined that the brake has insufficient torque available to hold the load. DO NOT TURN OFF POWER. This condition indicates that the brake has failed and the VFD / motor combination is suspending the load.
Page 116 Parameter Display Function Range Default C08-13 BE6 Maximum Pulse Total pulse counts must be less than C08-13, during C08-12, 0–2000 pulses Count otherwise BE6 alarm. C08-14 Brake Set Hold Speed Frequency the VFD outputs to push against the brake for BE2 0.0–25.5% CLV: 0.0 torque proving at start and the frequency the VFD outputs...
Page 117: Emergency Lift
5.2.20 Emergency Lift Emergency Lift (E-Lift) is a VG+ feature that allows operation of the VFD in the event of an encoder related fault (PGO-1-S/PGO-1-H) that resulted from a defective encoder, encoder cable, or PG-X3 option card. E-Lift can be enabled with C08-35 when the VFD is idle and not running.
Page 118 4. Conduct a Preliminary E-Lift Test: After all parameters have been configured in steps 2 and 3, the E-Lift function must be tested to ensure it can raise and lower a load properly. Conduct the following steps to verify the E-Lift function: DANGER If any undesired motions occur while E-Lift is active, immediately remove any RUN commands, turn off the E- Lift MFDI, and contact Magnetek.
Page 119: Slack Cable Detection
5.2.21 Slack Cable Detection Slack Cable Detection is a VG+ hoist function that monitors motor torque, while running at a steady speed, and detects when the torque suddenly dips below a set level (C11-03). Slack Cable Detection is not executed, unless both of the following conditions are true: •...
Page 120: Snap Shaft Detection
5.2.22 Snap Shaft Detection Snap Shaft Detection is designed to detect a broken or loose coupling by monitoring for a speed deviation between rotating shafts on a drive train. Ideally, mount one encoder on the motor, which drives the gearbox and one encoder on the last rotating part of the drive train, usually near the drum if used for a hoist motion.
Page 121: Brake Delay Timers
5.2.23 Brake Delay Timers The Brake Delay Timers are used in trolley and bridge applications to reduce the mechanical brake wear when positioning a load. This is a Traverse only function and B03-03 must be set to 4 (Decel With Timer). Table 5-39: Brake Delay Timers Parameter Settings Parameter Display...
Page 122: On/Off Delay Timers
5.2.24 On/Off Delay Timers • The timer function is enabled when the timer function MFDI (H01-0x = 43) and MFDO (H02-0x = 12) are both set. • These serve as general purpose I/O. Chattering of sensors, switches, contactors, etc., can be prevented with a delay time.
Page 123: Mfdo Delay Timer Function
Table 5-41: Maintenance Timers and Counters Parameter Settings Parameter Display Function Range Default C12-05 Maintenance Run Timer Timer increments while VFD is outputting 0–32000 Hrs current. Maintenance Gain (C12-06) is enabled when the timer exceeds the C12-05 hours. Reset the timer by keypad or MFDI = 7C. View monitor U04-28 for remaining hours.
Page 124: Inch Control
Figure 5-17: M1-M2 Delay Timer Example 5.2.27 Inch Control The Inch Control function can be enabled by programming H01-xx = 17, 18, or 19. The frequency reference used during inching is determined by B01-17 (Jog Reference). CAUTION A directional input is not needed to enable motion of the motor. Table 5-43: Inch Control Parameter Settings Parameter Display...
Page 125: Index Control
5.2.28 Index Control Index Control is an IMPULSE•VG+ Series 5 feature that allows for precise movement of the motor each time a run command is applied and the Index function is enabled by a digital input (H01-xx = 60). The total distance (Pulses) the motor will index is determined by the following equation: Pulse Total distance (Pulses) = [F01-01( ) * C13-04(Revs)] + C13-05(Pulses)
Page 126 Table 5-44: Index Control Parameter Settings Parameter Display Function Range Default C13-03 Index Frequency Index frequency reference (MFDI = 60) 0.01–60.00 Hz 1.00 Reference C13-04 Index Motor Revolutions Index motor revolutions 0–65535 Revs (F01-01 ppr = 1 motor revolution) C13-05 Index Motor Pulses Index fractional motor revolution.
Page 127: Sway Control
5.2.29 Sway Control Sway Control is a method to greatly reduce the amount of unwanted swing when moving suspended loads. It works by point-mass theory such that a suspended load behaves as a pendulum. The algorithm predicts how the system will react to movement and reshapes the motor speed commands to prevent unwanted swing. A 90%-95% swing reduction is typical, but better results can be achieved.
Page 128 Parameter Display Function Range Default C14-06 Acceleration Aggression Aggression scale of Acceleration. 0.0–10.0 0.0 is the least aggressive (slower). 10.0 is the most aggressive (faster). C14-07 Deceleration Aggression Aggression scale of Deceleration. 0.0–10.0 0.0 is the least aggressive (slower). 10.0 is the most aggressive (faster). C14-08 Sway Control in Micro- Disable Sway Control when Micro-Speed 1 or...
Page 129 5.2.29.1 Setting Up Sway Control ® The optimal Sway Control configuration includes an IMPULSE •VG+ VFD on the Hoist. With this configuration, the hook height can be dynamically relayed from the Hoist to the Traverse (sway control) VFDs. With an ®...
Page 130 ® Open Loop Hoist VFD Setup (Such as IMPULSE •G+ Series 5) The height of the hook is not known by the Hoist VFD due to lack of an encoder. In this configuration, a static hook height is programmed into the sway control VFDs, and sway control will function best when the hook is at that height.
Page 131 Swing Length Measurement The Hoist VFD is now setup to output the height of the hook as an analog signal. An analog input on each of the Traverse VFDs is programmed to read this value into the Sway Control function. This value will be scaled to determine the exact height of the hook.
Page 132 Table 5-47: Swing Time to Swing Length Conversion Table Swing Swing Swing Swing Swing Swing Swing Swing Length Length Length Length Time (sec) Time (sec) Time (sec) Time (sec) (feet) (feet) (feet) (feet) 15.5 2.25 6.75 11.25 15.75 11.5 2.75 7.25 11.75 16.25...
Page 133 5.2.29.3 Sway Control Expected Acceleration/Deceleration Times Table 5-48: Expected Acceleration/Deceleration Times (0-60 Hz) C14-06 (Accel) or C14-07 (Decel) Aggressiveness Swing Length [Unitless] (ft) 10.0 13.4 sec 11.4 sec 9.4 sec 7.4 sec 5.4 sec 3.4 sec 14.5 sec 12.5 sec 10.5 sec 8.5 sec 6.5 sec...
Page 134 5.2.29.4 Hoist Swing Length Diagram Figure 5-19: Hoist Swing Length Diagram IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 134...
Page 135: Tuning
5.3 Tuning • d01 DC Injection / Short Circuit Braking • d02 Slip Compensation • d03 Torque Compensation • d04 Automatic Speed Regulator (ASR) Tuning • d05 Torque Control • d08 Dwell • d09 S-Curve Acceleration/Deceleration • d10 Duty & Carrier Frequency 5.3.1 DC Injection / Short Circuit Braking With decel to stop enabled (b03-03 = 0), upon removal of the run command, the motor will decelerate according to the Decel Time (b05-02), until output frequency reaches the DC Injection Braking Start Frequency (d01-01).
Page 136: Slip Compensation
5.3.2 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. Parameter d02-01 sets the slip compensation gain. When d02-01 = 1.0, the output frequency is increased by 1% of the E01-06 setting at rated current.
Page 137: Torque Compensation
5.3.3 Torque Compensation The motor torque requirement changes according to load conditions. Full-range automatic torque boost adjusts the voltage of the V/f pattern according to the required torque. The VFD automatically adjusts the voltage during constant-speed operation as well as during acceleration. The required torque is calculated by the VFD.
Page 138: Automatic Speed Regulator (Asr) Tuning
5.3.4 Automatic Speed Regulator (ASR) Tuning The ASR controls the motor speed in the Closed Loop Vector control method and adjusts the output torque reference to minimize the difference between frequency reference and actual motor speed. The figure below illustrates ASR functionality: Figure 5-21: Speed Control Block Diagram for Closed Loop Vector Perform Auto-Tuning and set up all motor data correctly prior to adjusting ASR parameters.
Page 139 5.3.4.1 Adjusting the ASR Parameters in Closed Loop Vector The VFD is preset to use ASR settings d04-01/d04-02 over the entire speed range in Closed Loop Vector. If required by the application, a second set of ASR parameters (d04-03/d04-04) can be automatically activated depending on the motor speed or by using a digital input.
Page 140 Table 5-53: ASR Tuning Parameter Settings Parameter Display Function Range Default d04-01 ASR Proportional Gain 1 Proportional gain of the speed control loop. 0.00–300.00 20.00 d04-02 ASR Integral Time 1 Integral time of the speed control loop. 0.000–10.000 sec 0.500 d04-03 ASR Proportional Gain 2 Proportional gain 2 of the speed control loop.
Page 141: Torque Control
5.3.5 Torque Control Please consult factory for application assistance regarding torque control. Typically, torque control should not be applied on a hoist. This function is used to avoid excessive changes in torque, which may be caused by abnormal resonance when the torque reference changes rapidly.
Page 142 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 = 68). Table 5-55: Speed/Torque Control Switch Parameters Terminal Parameter Setting...
Page 143: 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-xx = 65. Table 5-56: Dwell Function Parameter Settings Parameter Display Function Range Default d08-01 Dwell Reference at Start Dwell frequency reference at start.
Page 144: 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. Table 5-57: S-Curve Acceleration/Deceleration Parameter Settings Parameter Display Function...
Page 145 Figure 5-26: S-Curve Characteristic-FWD/REV Operation IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 145...
Page 146: Duty & Carrier Frequency
5.3.8 Duty & Carrier Frequency The Duty & Carrier Frequency group configures the VFD’s output carrier frequency and overload level. CAUTION Consult Magnetek for VFD derating before modifying the d10 group parameters. Failure to do so may result in equipment damage. Table 5-58: Duty &...
Page 147: Motor Parameters
5.4 Motor Parameters • E01 V/f Pattern for Motor 1 • E02 Motor 1 Parameters • E03 V/f Pattern for Motor 2 • E04 Motor 2 Parameters • E07 Test Mode 5.4.1 Voltage/Frequency (V/f) Pattern for Motor 1 WARNING VFD input voltage (not motor voltage) must be set in E01-01 for the protective features of the VFD to function properly.
Page 148 Table 5-60: V/f Pattern for Motor 1 Parameter Settings Parameter Display Function Range Default E01-01 Input AC Supply VFD input voltage used as the max and base 230V: 155–255 VAC Voltage voltage by preset V/f patterns (E01-03 = 0 to 460V: 310–510 VAC E).
Page 149 Parameter Display Function Range Default E01-12 Mid Point B Voltage Midpoint Output Voltage B 230V: 0.0–255.0 Disabled when 0.0. 460V: 0.0–510.0 575V: 0.0–733.1 E01-13 Base Voltage Motor Base Voltage 230V: 0.0–255.0 Disabled when 0.0. 460V: 0.0–510.0 575V: 0.0–733.1 * Initial value determined by X-Press Programming (Table 4-6 on page 70, Table 4-7 on page 71 or Table 4-8 on page 72). NOTE: In Closed Loop Vector, E01-03 is hidden, and the V/f pattern values are adjusted during an Auto-Tune.
Page 150 Table 5-62: Voltage/Frequency (V/f) Pattern Options (230 V Models: 2025 to 2180) 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 14.4 60.0 230.0 60.0 15.7 60.0 230.0 60.0 16.8 60.0 230.0 60.0 18.0 60.0 230.0 60.0 19.3...
Page 151 Table 5-63: Voltage/Frequency (V/f) Pattern Options (230 V Models: 2215 to 2415) 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 12.1 60.0 230.0 60.0 13.4 60.0 230.0 60.0 14.5 60.0 230.0 60.0 15.7 60.0 230.0 60.0 17.0...
Page 152 Table 5-64: Voltage/Frequency (V/f) Pattern Options (460 V Models: 4001 to 4009) 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 31.1 16.8 60.0 460.0 60.0 33.6 19.1 60.0 460.0 60.0 35.9 21.4 60.0 460.0 60.0 38.2 24.0...
Page 153 Table 5-65: Voltage/Frequency (V/f) Pattern Options (460 V Models: 4014 to 4091) 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 28.8 12.2 60.0 460.0 60.0 31.3 14.5 60.0 460.0 60.0 33.6 16.8 60.0 460.0 60.0 35.9 19.4...
Page 154: Motor 1 Parameters
Table 5-66: Voltage/Frequency (V/f) Pattern Options (460 V Models: 4112 to 4605) 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 24.2 60.0 460.0 60.0 26.7 12.2 60.0 460.0 60.0 29.0 14.5 60.0 460.0 60.0 31.3 17.1 60.0...
Page 155 Motor terminal resistance E02-05 can be calculated by using the following equation: Table 5-67: Motor 1 Parameter Settings Parameter Display Function Range Default E02-01 Motor Rated Current (FLA) Motor-rated current E02-02** Motor Rated Slip Motor-rated slip frequency 0.000–20.000 Hz E02-03** Motor No-Load Current Motor no-load current 0.00–(E02-01–0.01) A...
Page 156: Voltage/Frequency (V/F) Pattern For Motor 2
5.4.3 Voltage/Frequency (V/f) Pattern for Motor 2 The Motor 2 function allows for a secondary motor to be enabled and controlled by the VFD. This motor may serve as a backup to the primary motor, for redundancy. To enable Motor 2, configure an MFDI to H01-xx = 16 (Motor 2 Selection). Table 5-68: Motor 2 Parameter Settings Parameter Display...
Page 157: Motor 2 Parameters
5.4.4 Motor 2 Parameters These parameters define the Motor 2 characteristics. Table 5-69: Motor 2 Parameter Settings Parameter Display Function Range Default E04-01 Motor 2 Rated Current Motor-rated current E04-02 Motor 2 Rated Slip Motor-rated slip frequency 0.000–20.000 Hz E04-03 Motor 2 No-Load Current Motor no-load current 0.00–(E04-01–0.01) A...
Page 158 Table 5-70: Test Mode Parameter Settings Parameter Display Function Range Default E07-00 Test Mode Test Mode Enable. Starts a 10 minute timer 0, 1 after which the VFD will not function until Test 0 Disabled Mode is disabled. If power is cycled, Test Mode 1 Enabled will become disabled.
Page 159: Option Card Parameters
5.5 Option Card Parameters • F01 Encoder Feedback (PG-X3) Option Card Setup • F04 Analog Output (AO-A3) Option Card Setup • F05 Digital Output (DO-A3 or S4IO) Option Card Setup • F06 Communication Option Card Settings and Profibus-DP (SI-P3) Option Card Setup •...
Page 160 Parameter Display Function Range Default F01-22 Encoder Open-Circuit PGO-1-S disconnection detection time. A setting of 0.0–10.0 sec Detect Time zero disables PGO-1-S detection. F01-23 Overspeed Detection Overspeed (OS) fault stopping method. Traverse: 0–3 Selection NLB: 1 0 Decel to Stop Decelerate to stop using the decel time in b05-02.
Page 161: Digital Input (Di-A3 Or S4Io) Option Card Setup
5.5.2 Digital Input (DI-A3 or S4IO) Option Card Setup Selects the digital input functions for the DI-A3 or S4IO option cards. Table 5-72: DI-A3/S4IO Parameter Settings Parameter Display Function Range Default F03-01 Digital Input Option Provides additional programmable MFDI 0–2, 5 0 Disabled No additional MFDI are enabled.
Page 162: Analog Output (Ao-A3) Option Card Setup
5.5.3 Analog Output (AO-A3) Option Card Setup Selects the analog output functions for the AO-A3 option card. Table 5-73: AO-A3 Parameter Settings Parameter Display Function Range Default F04-01 Terminal V1 Function Selection Terminal V1 function 1–631 F04-02 Terminal V1 Gain Terminal V1 gain -999.9–999.9% 100.0...
Page 163: Communication Option Card Settings
5.5.5 Communication Option Card Settings These parameters are used to set the basic communication settings and method of fault detection for the communication option cards. Table 5-75: Communication Option Card Settings Parameter Settings Parameter Display Function Range Default F06-01 Communication Error Action or stopping method when an Open 0–5 Selection...
Page 164 Parameter Display Function Range Default F06-14 BUS Error Auto Reset Automatic reset function for bUS error. 0, 1 0 Disabled 1 Enabled F06-15 Comm. Option Parameters Update method when an F06-xx or F07-xx 0–2 Reload parameter is changed. 0 Reload at Next Power Cycle 1 Reload Now 2 Cancel Reload Request...
Page 165: Profibus-Dp (Si-P3) Option Card Setup
5.5.6 Profibus-DP (SI-P3) Option Card Setup Settings for the Profibus-DP communication option card SI-P3. Table 5-76: SI-P3 Parameter Settings Parameter Display Function Range Default F06-30 PROFIBUS-DP Node Node address 0–125 Address F06-31 PROFIBUS-DP Clear Mode Determines the operation when a “Clear 0, 1 Selection Mode”...
Page 166: Ethernet/Ip (Si-En3), Profinet (Si-Ep3), And Modbus Tcp/Ip (Si-Em3) Option Card Setup
5.5.7 Ethernet/IP (SI-EN3), ProfiNET (SI-EP3), and Modbus TCP/IP (SI-EM3) Option Card Setup Settings for Ethernet/IP (SI-EN3), ProfiNET (SI-EP3), and Modbus TCP/IP (SI-EM3) option cards. Table 5-77: SI-EN3/SI-EP3/SI-EM3 Parameter Settings Parameter Display Function Range Default F07-01 IP Address 1 IP Address 1 0–255 F07-02 IP Address 2...
Page 167 Parameter Display Function Range Default F07-19 EtherNet/IP Torque Scaling factor for EtherNet/IP torque monitor -15–15 Scale Factor F07-20 EtherNet/IP Power Scaling factor for EtherNet/IP power monitor -15–15 Scaling Factor F07-21 EtherNet/IP Voltage Scaling factor for EtherNet/IP voltage monitor -15–15 Scale Factor F07-22 EtherNet/IP Time Scaling factor for EtherNet/IP time monitor...
Page 168: Control I/O Parameters
5.6 Control I/O Parameters • H01 Digital Inputs • H02 Digital Outputs • H03 Analog Inputs • H04 Analog Outputs • H05 Modbus Communication • H06 Pulse Train Input/Output • H07 Virtual Inputs/Outputs 5.6.1 Digital Inputs The VFD has eight multi-function digital inputs for numerous functions. The following table lists the function selections for Terminals S1 to S8.
Page 169 Table 5-79: Multi-Function Digital Input (MFDI) Selections for H01-0x and F03-0x NOTE: Some settings have a normally open (N.O.) and normally closed (N.C.) option. The normally open option will be a setting below 100. The normally closed option is 100 above that. Setting Display Function...
Page 170 Setting Display Function Load Float Run for C04-01 ON: Load Float initiated for time duration C04-01 (Load Float Run Time) Requires a run command or that the VFD is already running. ASR Gain Select ON: Uses ASR Proportional Gain 2 (d04-03) OFF: Uses ASR Proportional Gain 1 (d04-01) Accel/Decel Ramp Hold ON: Acceleration/deceleration is stopped, and frequency is held.
Page 171 Setting Display Function Load Share Follower Ready ON: Load Share follower ready signal received. Loss of this signal while running will result in an FNR fault. Load Check Bypass ON: Disables Load Check and clears any LC faults Brake 2 Answerback ON: Brake answerback feedback received from Brake 2.
Page 172 Setting Display Function Weighted Limit Fault UL3 (N.C.) OFF: Weighted Upper Limit 3 stop limit reached. Keypad displays UL3 fault. Uses C03-10 stopping method and requires fault reset. Ultra-Lift Enable OFF: Ultra-Lift enabled This input is used when C06-01 = 2 or 4. Not available for Traverse motions. Alternate Torque Limit Gain OFF: Torque Limit Gains (C07-05 to C07-07) added to C07-01 to C07-04.
Page 173 Setting Display Function Sway Control Aux Hoist OFF: Sway Control enabled with Aux Hook Height Used when C14-01 = 2 (Enabled by MFDI) and the motor is stopped. Enabling or disabling this input is not recommended while the motor is running. Hook height determined by H03-xx = 21 (Aux Hook Height) analog input.
Page 174 Table 5-81: F1, F2, and F3 Key Functions Display Function Instruction Alert/Confirm Message F Not Used Function key is disabled 53 Communications Test Communication Test Mode - Hold down the F key for 2-3 Running: Mode loopback test of Modbus RS- seconds to initiate the Comm Comm Test Mode 485 interface...
Page 175 5.6.1.2 Digital Inputs—Secondary Functions The parameters in this section allow the selection of a secondary function for the S1 to S8 digital input terminals. An OPE03 error will occur if a function is programmed to more than one terminal at the same time. Table 5-82: Digital Inputs Secondary Functions Parameter Settings Parameter Display...
Page 176: Digital Outputs
5.6.2 Digital Outputs The VFD 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. Table 5-84: Digital Outputs Parameter Settings Parameter Display Function Range Default H02-01...
Page 177 Table 5-85: Multi-Function Digital Output (MFDO) Selections 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 OFF: Motor Speed >...
Page 178 Display Function 1A Forward Direction ON: During Forward/Up operation OFF: Running in Reverse/Down direction or baseblock 1B During Reverse ON: During Reverse/Down operation OFF: Running in Forward/Up direction or baseblock 1C Ultra-Lift Active ON: VFD is operating in Ultra-Lift OFF: VFD is not operating in Ultra-Lift 1D Braking Transistor Fault ON: VFD detects a braking resistor or transistor failure.
Page 179 Display Function 30 Load Check Detected ON: VFD has detected a Load Check fault OFF: Normal operation 31 Slack Cable Detected ON: VFD has detected a Slack Cable OFF: Normal operation 32 Snap Shaft Detected ON: VFD has detected a Snap Shaft OFF: Normal operation 34 Index Complete ON: Index move is complete...
Page 180 5.6.2.1 Digital Outputs—Alarm/Fault Annunciate (H02-01–03 = 40 through 43) Fault Annunciate enables you to assign a set of eight fault/alarm outputs to Relay Outputs M1-M2, M3-M4, and M5-M6. M1-M2 is typically assigned to a brake output, but it could instead be used for fault annunciate. This function will also trigger the MA-MB-MC fault relay.
Page 181 Example: Select a Set containing the alarm/fault(s) you want to trigger an output. You can only select from one set. If you want a relay output based on only LL1 and LL2, you would choose Set 1. 1. Set relay M5-M6 to H02-03 = 43 (Fault Annunciate 4). 2.
Page 182 Table 5-88: Binary to Hexadecimal Conversion Binary Number Hexadecimal Value Binary Number Hexadecimal Value 0000 1000 0001 1001 0010 1010 0011 1011 0100 1100 0101 1101 0110 1110 0111 1111 5.6.2.2 Digital Outputs—Modbus The parameters in this section configure digital outputs using the serial Modbus protocol. Table 5-89: Modbus Digital Outputs Parameter Settings Parameter Display...
Page 183 5.6.2.3 Digital Outputs—Secondary Functions The parameters in this section allow the selection of a secondary function for the M1-M2, M3-M4, and M5-M6 digital output relays. Additional parameters are available for delay times and logical operation options for the secondary functions. Table 5-90: Digital Outputs Secondary Functions Parameter Settings Parameter Display...
Page 184: Analog Inputs
5.6.3 Analog Inputs The VFD has three built-in analog inputs for the external input of references and limits. Table 5-91: Analog Inputs Parameter Settings Parameter Display Function Range Default H03-01 Terminal A1 Signal Terminal A1 analog input signal 0–3 Level Select 0 0 to 10 V 1 -10 to 10 V 2 4 to 20 mA...
Page 185 Parameter Display Function Range Default H03-19 4-20mA Feedback If a 4-20 mA analog input is less than 2 mA for 0.0–2.0 sec Loss Time this set time, an AFbL fault will occur. A setting of 0.0 disables this function. * Initial value is determined by X-Press Programming (Table 4-6 on page 70, Table 4-7 on page 71 or Table 4-8 on page 72). 5.6.3.1 Analog Inputs—Modbus The parameters in this section configure analog inputs using the serial Modbus protocol.
Page 186 Table 5-93: Multi-Function Analog Input (MFAI) Selections for H03-02, -06, and -10 Setting Display Function Analog Frequency Reference 1 Analog Frequency Reference 1 10V = E01-04 (maximum output frequency) Frequency Gain Analog frequency reference is multiplied with the Frequency Gain. Analog Frequency Reference 2 Analog Frequency Reference 2 10V = E01-04 (maximum output frequency)
Page 187: Analog Outputs
5.6.4 Analog Outputs The VFD has two built-in analog outputs for condition monitoring. Analog output capabilities can be increased with the installation of an AO-A3 option. Table 5-94: Analog Outputs Parameter Settings Parameter Display Function Range Default H04-01 Terminal FM Analog Output Select Function for Terminal FM.
Page 188 Parameter Display Function Range Default H04-01 428 Run Time Remaining 000–631 430 On Time Remaining 433 Brake Cycles Remaining 452 Torque Reference from Comm 601 Iq Secondary Current 602 Id Excitation Current 603 ASR Input 604 ASR Output 605 Output Voltage Reference (Vq) 606 Output Voltage Reference (Vd) 607 q-Axis ACR Output 608 d-Axis ACR Output...
Page 189: Modbus Communication
5.6.5 Modbus Communication The VFD uses terminals D+ and D- to communicate the Modbus (RS-485) protocol. Cycle power after changing any of these parameters. NOTE: The Modbus RS-422 protocol is not compatible. Table 5-95: Modbus Communication Parameter Settings Parameter Display Function Range Default...
Page 190 Parameter Display Function Range Default H05-11 Comm ENTER Command Enter command function via serial. 0, 1 Mode 0 ENTER Command VFD requires an Enter command before Required accepting any parameter changes. 1 ENTER Command Not Parameter changes are activated Required immediately without the Enter command.
Page 191: Pulse Train Input/Output
5.6.6 Pulse Train Input/Output Pulse Input and Output provides speed control capabilities via the RP and MP terminals. Table 5-96: Pulse Train Input/Output Parameter Settings Parameter Display Function Range Default H06-01 Terminal RP Pulse Train Terminal RP pulse input 0, 3, 5 Function 0 Frequency Reference Set B03-01 = 4 (Pulse Input) to enable RP.
Page 192: Virtual Inputs/Outputs
5.6.7 Virtual Inputs/Outputs Virtual inputs and outputs allow for the passing of information without the need for external wiring. This function performs the following: • Inputs the result of the output from the MFDO terminal to the MFDI terminal without external wiring. •...
Page 193: Protection Parameters
5.7 Protection Parameters • L01 Motor Protection • L02 Power Loss Ride Through • L03 Stall Prevention • L04 Speed Detection • L06 Torque Detection • L08 Hardware Protection • L09 Automatic Fault Reset • L09 Fault Latch 5.7.1 Motor Protection The VFD has an electronic overload protection function (OL1) for protecting the motor from overheating.
Page 194 Parameter Display Function Range Default L01-03 Motor Thermistor oH Operation when the motor temperature analog 0–3 Alarm Select input (H03-02, H03-06, or H03-10 = E) exceeds the oH3 alarm level. (1.17V) 0 Decel to Stop 1 Coast to Stop 2 Fast Stop (Use b05-08) Decel by b05-08 3 Alarm Only oH3 Flashes...
Page 195: Power Loss Ride Through
5.7.2 Power Loss Ride Through Table 5-99: Power Loss Ride Through Parameter Settings Parameter Display Function Range Default L02-01 Power Loss Ride Through Enables/disables the Power Loss Ride 0–2 Select thru function 0 Disabled UV1 fault when power is lost for more than 15 milliseconds.
Page 196: Stall Prevention
Parameter Display Function Range Default L02-31 KEB Start Voltage Offset Level KEB start voltage offset. 230V: 0–100 VDC Depends 460V: 0–200 VDC on A01-02 575V: 0–287 VDC 5.7.3 Stall Prevention Table 5-100: Stall Prevention Parameter Settings Parameter Display Function Range Default L03-01 Stall Prevention during...
Page 197: Speed Detection
Parameter Display Function Range Default L03-23 Stall P Reduction at Reduces the Stall Prevention during run level in 0, 1 Constant HP the constant power range. (G+ only) 0 Use L3-06 for Entire Sets the Stall Prevention level that is used Speed Range throughout the entire frequency range.
Page 198 Speed Agree 2 • When enabled using MFDO “H02-xx = 13”, the contact closes when the output frequency (U01-02) is equal to the frequency reference (U01-01) plus or minus the speed agree detection width (L04-04). • U01-02 = (U01-01 ± L04-04) •...
Page 199: Torque Detection
Table 5-102: Frequency Detection Parameter Settings Parameter Display Function Range Default L04-05 Fref Loss Detection Selection The VFD can detect a loss of an analog 0, 1 frequency reference from input A1, A2, or A3. Frequency reference loss is detected when the reference is less than 10% in 400 ms.
Page 200 Table 5-104: Torque Detection 1 (L06-01) Setting Descriptions Settings Description Torque detection is disabled (factory default). Overtorque detection is enabled whenever at speed agree (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 speed agree.
Page 201 Table 5-106: Torque Detection 2 (L06-04) Setting Descriptions Settings Description Overtorque/undertorque detection is disabled (factory default). Overtorque detection is enabled whenever at speed agree (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 speed agree.
Page 202 Table 5-108: Mechanical Fatigue (L06-08) Setting Descriptions 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 203: Hardware Protection
5.7.6 Hardware Protection The IMPULSE•G+/VG+ Series 5 has several built-in functions designed to protect the VFD and its components from damage. Table 5-110: Hardware Protection Parameter Settings Parameter Display Function Range Default L08-02 Overheat Alarm Level Heatsink temperature level for protection against 50–150°C 105* overheat (OH).
Page 204 Parameter Display Function Range Default L08-15 Drive oL2 @ Low Speed OL2 detection when output frequency ≤ 6 Hz 0, 1 Protection 0 Disabled 1 Enabled L08-18 Software Current Limit Software current limit 0, 1 Selection 0 Disabled 1 Enabled L08-19 Freq Reduction @ oH Frequency reference reduction gain at overheat...
Page 205: Automatic Fault Reset
5.7.7 Automatic Fault Reset When a fault occurs during operation, it can be automatically reset. Table 5-111: Automatic Fault Reset Parameter Settings Parameter Display Function Range Default L09-01 Auto Fault Reset Number of auto fault reset attempts. 0–10 Attempts Reset attempt counter is returned to zero if no faults occur within a ten minute period.
Page 206 Table 5-114: Binary to Hexadecimal Conversion Binary Number Hexadecimal Value 0000 0001 0010 0011 0100 0101 0110 0111 1000 1001 1010 1011 1100 1101 1110 1111 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 206...
Page 207: Special Adjustment
5.8 Special Adjustment • n01 Hunting Prevention • n02 Auto Frequency Regulator (AFR) 5.8.1 Hunting Prevention Hunting Prevention is a feature available for the V/f control method only. Occasionally, 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 208: Auto Frequency Regulator (Afr)
Parameter Display Function Range Default n01-17 Hunting Prevent High Fc Hunting prevention responsiveness. Enable by 0–1000 ms Filter setting N01-01 = 2. n01-20 Voltage Calibration Voltage calibration time at start. 10–500 ms Duration 5.8.2 Auto Frequency Regulator (AFR) The Automatic Frequency Regulator (AFR) is a speed feedback detection reduction function for Open Loop Vector that helps with speed stability during sudden load changes.
Page 209: Keypad And Vfd Configuration
5.9 Keypad and VFD Configuration • o01 Keypad Display • o02 Keypad Operation • o03 Maintenance Monitors • o06 User Stored Data 5.9.1 Keypad Display The home screen of the keypad can be configured to display various monitors. A maximum of three selected monitors will fit on each screen, and arrow keys can be used to navigate between screens.
Page 210 Parameter Display Function Range Default o01-44 2nd Monitor Area Setting Horizontal axis value used to display the 0.0–100.0% 100.0 monitor set in o01-25 (Custom Monitor 2) as a bar graph. o01-45 3rd Monitor Area Horizontal range used to display the monitor 0, 1 Selection set in o01-26 (Custom Monitor 3) as a bar...
Page 211: Keypad Operation
5.9.2 Keypad Operation Table 5-118: Keypad Operation Parameter Settings Parameter Display Function Range Default o02-01 LO/RE Key Function Selection Pressing the LO/RE Key once displays: “Call 0, 1 Magnetek at 1-866-624-7378”. 0 Mode/Service Firmware Version (U01-14) VFD Specifications Pressing the LO/RE Key a second time: Control Method (A01-02) Motion (A01-03) Speed Reference (A01-04)
Page 212 Parameter Display Function Range Default o02-04 92 4001 4001-G+/VG+S5 00–FF 93 4003 4003-G+/VG+S5 94 4004 4004-G+/VG+S5 95 4005 4005-G+/VG+S5 96 4007 4007-G+/VG+S5 97 4009 4009-G+/VG+S5 99 4014 4014-G+/VG+S5 9A 4018 4018-G+/VG+S5 9C 4024 4024-G+/VG+S5 9D 4031 4031-G+/VG+S5 9E 4039 4039-G+/VG+S5 9F 4045 4045-G+/VG+S5 A1 4060...
Page 213: Maintenance Monitors
Parameter Display Function Range Default o02-24 LED Light Function Selection Function of the LED status rings and keypad LED 0–2 lights. 0 Enable Status Ring & Keypad 1 LED Status Ring Disable 2 Keypad LED Light Disable o02-26 Alarm Display at Ext. 24V Display an (EP24v) alarm if the main supply 0, 1 Power...
Page 214: User Stored Data
Parameter Display Function Range Default o03-14 Clear OL/LC/OW Counter Reset the Overload (OL), Load Check (LC), 0, 1 and Overweight (OW) fault counter (U01-73). 0 No Reset Not cleared. 1 Reset Resets the U01-73 counter. o03-22 Time Format Time display format. 0–2 0 24 Hour Clock 1 12 Hour Clock...
Page 215: Monitors
5.10Monitors • U01 Operation Status • U02 Fault Trace • U03 Fault History • U04 Maintenance • U06 Control Status Table 5-121: Operation Status Monitors Monitor Display Function Units U01-01 Frequency Reference Frequency Reference U01-02 Output Frequency Output Frequency U01-03 Output Current Output Current U01-04...
Page 216 Monitor Display Function Units U01-12 Drive Status Operation Status U01-14 Software Number Flash Firmware version U01-15 Terminal A1 Level External Terminal A1 Input level U01-16 Terminal A2 Level External Terminal A2 Input level U01-17 Terminal A2 Level External Terminal A3 Input level U01-20 SFS Output Frequency Output frequency after the soft starter...
Page 217 Monitor Display Function Units U01-61 Encoder 2 Pulse Counter Raw PG Channel 2 pulse count Pulses 4 pulses = 1 ppr of F01-01 U01-68 Load Check Zone Load Check zone the VFD is currently running in when an LC fault occurs.
Page 218 Table 5-123: Fault History Monitors Monitor Display Function Units U03-01 1st Most Recent Fault First most recent fault U03-02 2nd Most Recent Fault Second most recent fault U03-03 3rd Most Recent Fault Third most recent faults U03-04 4th Most Recent Fault Fourth most recent fault U03-05 5th Most Recent Fault...
Page 219 Monitor Display Function Units U04-10 kWh, Lower 4 Digits VFD output power. The value is a 9 digit number displayed across two monitors, U04-10 and U04-11. U04-11 kWh, Upper 5 Digits U04-13 Peak Hold Current Highest current value that occurred during run. U04-14 Peak Hold Output Output frequency when the value shown in U04-13 occurred.
Page 220 Monitor Display Function Units U04-33 Brake Cycles Remaining Keypad displays the LONG integer of U04-31. Modbus register stores the LOWER word of Brake Cycles Remaining. Reset using MFDI or keypad function button. U04-49 Password Challenge Challenge code for temporary Factory password. U04-52 Torque Reference from Torque reference received from a communication option card or...
Page 221 IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 221...
Page 222: 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 This section describes basic maintenance and inspection procedures for the VFD.
Page 223 Table 6-2: Motor Related Issues 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. Verify that the keypad display is not showing a fault. 3.
Page 224 Display 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 236. started to accelerate the motor when it detects excessive encoder feedback.
Page 225 Display Description Corrective Action Fault Alarm BE7-2 Brake 2 Answerback Fault. 1. Check if brake is closed. Brake 2 Welded 2. Check brake answerback Brake Answerback is on at power-up. circuitry. Brake Slipping Alarm. The BE8 alarm indicates 1. Check the brake. that the VFD has detected excessive encoder Brake Slipping 2.
Page 226 Display Description Corrective Action Fault Alarm CPF03 Control Board Connection Error. Connection Error: CPU Serial Err Connection error between the control board and 1. Turn off the power and check the VFD. Can be caused by a connection error, or the connection between the the VFD failing to operate properly due to noise control board and the VFD.
Page 227 Display Description Corrective Action Fault Alarm CPF22 Hybrid IC Failure. Hybrid IC failure on the power 1. Cycle power to the VFD. board. Internal A/D Err 2. If the problem continues, replace the control board or the entire VFD. Contact Magnetek for instructions on replacing the control board.
Page 228 Display Description Corrective Action Fault Alarm External fault occurs on Terminal S2. 1. Check H01-02 for proper programming. External Fault 2 Alarm or fault defined by the External Fault 2. Check the conditions for input Selection table (Table 5-88 on page 182). terminal S2.
Page 229 Display Description Corrective Action Fault Alarm HBB or HBBf Hardware Baseblock. The flashing Hardware 1. Check signal status at the Baseblock signal is a result of either of the Safe input terminals H1 and H2. Hardware Disable inputs being open. The motor will begin Baseblock 2.
Page 230 Display Description Corrective Action Fault Alarm Over Current Detected. Output current exceeds 1. Check for a phase-to-phase 200% of VFD rated output current. short in the motor or wiring Over Current using a megger. 2. Extend the acceleration/ deceleration time. 3.
Page 231 Display Description Corrective Action Fault Alarm Overvoltage Fault. The main circuit direct 1. Extend the deceleration time. current voltage exceeded the overvoltage level. DC Bus Overvolt 2. Check DBU operation. 3. Check the resistor. 4. Check the line voltage. Overvoltage Fault. Overvoltage occurs during Check the line voltage.
Page 232 Display Description Corrective Action Fault Alarm Slack Cable Fault. A hoist slack cable condition 1. May not require corrective occurred. action. Slack Cable Detection 2. Check setting of Slack Cable Detection (C11-xx). SNAP Snapped Shaft Fault. A drive train discontinuity 1.
Page 233 Display Description Corrective Action Fault Alarm MC Fault. The pre-charge contactor opened 1. Check power wiring. during operation. MC Answerback 2. Correct the line voltage. 3. Check collector system. 4. Wait 30-45 seconds before restarting VFD. Output Voltage Detection Fault. Replace the VFD.
Page 234 Table 6-4: Operation Error Table Display Description Corrective Action oPE01 VFD Capacity Setting Error. VFD kVA setting Check that o02-04 matches the VFD model. range is incorrect. oPE02 Setting Out of Range Error. Parameter setting is 1. With the fault displayed on the keypad, press out of range.
Page 235 Display Description Corrective Action oPE13 Pulse Monitor Selection Error. Check parameters H06-06 and H06-07. H06-06 = 101, 102, 105, or 116 (Terminal MP Monitor Selection = Frequency Reference, Output Frequency, Motor Speed, or SFS Output Frequency) has not been set when H06-07 = 0 (Terminal MP Frequency Scaling = 0 Hz).
Page 236: Troubleshooting Encoder And Brake Faults And Alarms
6.2 Troubleshooting Encoder and Brake Faults and Alarms The faults and alarms in this section may involve the encoder feedback or motor brake system. During system startup, these faults and alarms are often caused by parameters that need to be adjusted. However, if the system has been running for some time, 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 237: Pgo-X-S/Pgo-X-H-Pulse Generator Signal Fault
6.2.2 PGO-X-S/PGO-X-H–Pulse Generator Signal Fault Definition A Pulse Generator Signal fault indicates that the VFD has detected a problem with encoder feedback. This fault will typically occur if the VFD doesn’t receive any encoder feedback pulses while it is commanded to run or encoder wiring has a discontinuity.
Page 238: Be1-Rollback Fault
6.2.3 BE1–Rollback Fault Definition A 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 239: Be3-Brake Release Fault
6.2.5 BE3–Brake Release Fault Definition The BE3 fault indicates that the VFD has released the brake and commanded the VFD to run, but has not detected the expected encoder feedback. A BE3 fault will occur if the pulses received during the BE3 detection time (C08- 06) are less than the expected number of pulses (C08-07).
Page 240: Be6-Brake Proving Alarm
6.2.6 BE6–Brake Proving Alarm 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 241: Be8-Brake Slipping Alarm
6.2.7 BE8–Brake Slipping Alarm Definition A BE8 alarm indicates that the VFD has detected that the brake is slipping after the brake is set. A BE8 alarm will occur if the load is moving greater than the Brake Slip Detection Speed (C08-23) when the brake is set. When this occurs, the VFD will go into load float while the brake is set.
Page 242: Auto-Tuning Errors
6.3 Auto-Tuning Errors The following are errors during auto-tuning and corrective actions. If any of the following errors are detected, the keypad will display the error text and the motor will coast to stop, if running. No fault or alarm output is triggered. Table 6-5: Error Display and Corrective Actions Display Description...
Page 243 Display Description Corrective Action End 2 Motor Iron Core Saturation Coefficient Error • Check the Auto-Tune parameters. (Rotational tuning only). Since the motor iron • Check motor wiring. core saturation coefficient could not be auto-tuned • Disconnect the motor from the load. within the set time, tentative value is set in the iron core saturation coefficient.
Page 244: Option Card Faults
6.4 Option Card Faults Check the following items first when an option card fault occurs on the VFD: • Communication cable connections. • Make sure the option card is properly installed to the VFD. • Did a momentary power loss interrupt communications? Figure 6-1: Option Card Ports IMPULSE•G+/VG+ Series 5 Technical Manual August 2023...
Page 245 Table 6-6: Fault Codes for Option Cards Display Card Description Cause Possible Solution oFA00 Option Error (CN5-A). Option • The option card • Confirm that the VFD supports AO-A3 Card Connection Error at Port installed into port the option card. DI-A3 CN5-A.
Page 246 Display Card Description Cause Possible Solution oFA03 Option Card Fault at Option Port • Option card or • Cycle power to the VFD. AO-A3 CN5-A. hardware is damaged. • If the problem continues, DI-A3 replace the option card, control oFA17 DO-A3 board or the entire VFD.
Page 247: Copy Function Errors
6.5 Copy Function Errors 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. Note that errors related to the Copy function do not trigger the fault relay.
Page 248: Power Section Check
6.6 Power Section Check WARNING Do NOT touch any circuit components while main power is on or immediately after main power is turned off. You must wait until the red “CHARGE” lamp is extinguished, which may take up to 10 minutes for the DC bus voltage to drop to a safe level.
Page 249 6.7 Terminal Board (24 VDC) 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 VFD. 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 250 Appendix A: Parameter Listing Modbus Parameter Parameter Name Default Range Units Reference (Hex.) A01-01 Access Level Selection 0–3 0101 Page 67 G+: 0 A01-02 Control Method Selection 0, 2, 3 0102 Page 67 VG+: 3 G+: 1 A01-03 Motion 0–2 1600 Page 68 VG+: 2...
Page 251 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) A02-28 User Parameter 28 0121 Page 74 A02-29 User Parameter 29 0122 Page 74 A02-30 User Parameter 30 0123 Page 74 A02-31 User Parameter 31 0124 Page 74 A02-32 User Parameter 32 0125 Page 74 b01-01...
Page 252 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) b03-16 Run Command Selection 2 0–3 01C5 Page 85 b03-35 Digital Input Deadband Time 0.0–100.0 1117 Page 85 b05-01 Acceleration Time 1 5.00* 0.00–60.00 0200 Page 87 b05-02 Deceleration Time 1 3.00* 0.00–60.00 0201...
Page 253 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) C03-02 UL0/UL1 Deceleration Time 0.0–25.5 1624 Page 95 C03-03 UL2 Deceleration Time 0.0–25.5 1625 Page 95 C03-04 LL1 Speed 6.00 0.00–E01-04 1626 Page 95 C03-05 LL0/LL1 Deceleration Time 0.0–25.5 1627 Page 95 C03-06 LL2 Deceleration Time 0.0–25.5...
Page 254 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) C03-61 Hook Height Point 1 Revolutions 0–65535 Revs 164A Page 102 C03-62 Hook Height Point 2 Function 0–2 164B Page 102 C03-63 Hook Height Point 2 Revolutions 0–65535 Revs 164C Page 102 C04-01 Load Float MFDI Run Time 0–65535...
Page 255 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) C06-05 Ultra-Lift Reverse Torque 0–100 1654 Page 107 C06-06 Ultra-Lift Enabling Speed 59.0 0.1–300.0 1655 Page 108 C06-07 Ultra-Lift Delay Time 0.0–25.5 1656 Page 108 C06-08 Ultra-Lift Accel Multiplier 0.1–9.9 1657 Page 108 C06-10 Motor Torque QuickSet...
Page 256 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) C08-07 BE3 Brake Release Pulse Count 0–2000 Pulses 16B5 Page 115 C08-08 BE3 Reverse Torque Limit 0–250 16B6 Page 115 C08-09 Zero Speed Level 0.0–5.0 16B7 Page 115 C08-10 Load Float Time 0–65535 16B8 Page 115...
Page 257 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) C11-12 Snap Shaft Gear Ratio Numerator 10000 1–65535 169D Page 120 C11-13 Snap Shaft Gear Ratio Denominatr 10000 1–65535 169E Page 120 C12-01 Brake Set Delay @ Jog 0.0–100.0 169F Page 121 C12-02 Brake Set Delay @ Run 0.0–100.0...
Page 258 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) C14-09 Alternate Hook Height 0–300 16C8 Page 128 C14-11 End at Zero Speed 0–1 16CA Page 128 C14-12 Trav Limit Decel Method 0–2 16CB Page 128 d01-01 DC Injection/Zero SpeedThreshold 0.5 0.0–10.0 0189 Page 135...
Page 259 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) d04-01 ASR Proportional Gain 1 20.00 0.00–300.00 021B Page 140 d04-02 ASR Integral Time 1 0.500 0.000–10.000 021C Page 140 d04-03 ASR Proportional Gain 2 20.00 0.00–300.00 021D Page 140 d04-04 ASR Integral Time 2 0.500 0.000–10.000...
Page 260 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) 230V: 240 230V: 155–255 E01-01 Input AC Supply Voltage 460V: 480 460V: 310–510 0300 Page 148 575V: 575 575V: 446–733 V/f: 0–9, A–F, FF E01-03 V/f Pattern Selection 0302 Page 148 OLV: F, FF E01-04 Maximum Output Frequency...
Page 261 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) Motor 2 Maximum Output E03-04 60.0 20.0–300.0 031A Page 156 Frequency 230V: 0.0–255.0 E03-05 Motor 2 Maximum Output Voltage 460V: 0.0–510.0 031B Page 156 575V: 0.0–733.1 E03-06 Motor 2 Base Frequency 60.0 0.0–300.0 031C...
Page 262 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) E07-06 Test Mode Base Frequency 60.0 0.0–300.0 06F6 Page 158 Depends on E07-07 Test Mode Mid Point A Frequency 0.0–300.0 06F7 Page 158 E01-03 230V: 0.0–255.0 Depends on E07-08 Test Mode Mid Point A Voltage 460V: 0.0–510.0 06F8 Page 158...
Page 263 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) F03-05 Digital Input 4 Function 0–19F 167B Page 161 F03-06 Digital Input 5 Function 0–19F 167C Page 161 F03-07 Digital Input 6 Function 0–19F 167D Page 161 F03-08 Digital Input 7 Function 0–19F 167E Page 161...
Page 264 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) F06-16 Gateway Mode 0–4 0B52 F06-30 PROFIBUS-DP Node Address 0–125 03CB Page 165 PROFIBUS-DP Clear Mode F06-31 0–1 03CC Page 165 Selection F06-32 PROFIBUS-DP Data Format Select 0 0–5 03CD Page 164 F07-01 IP Address 1 0–255...
Page 265 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) Modbus Address F07-29 DOA116 7 0371 Page 167 0x---- Modbus Address F07-30 DOA116 8 0372 Page 167 0x---- Modbus Address F07-31 DOA116 9 0373 Page 167 0x---- Modbus Address F07-32 DOA116 10 0374 Page 167 0x----...
Page 266 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) Modbus Address F07-68 PZD9 Write 0788 Page 167 0x---- Modbus Address F07-69 PZD10 Write 0789 Page 167 0x---- Modbus Address F07-70 PZD1 Read (Status Word) 078A Page 167 0x---- Modbus Address F07-71 PZD2 Read (Output Frequency) 078B...
Page 267 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) H01-27 Terminal S7 Function Select 2 0–81 0B76 Page 175 H01-28 Terminal S8 Function Select 2 0–81 0B77 Page 175 H01-40 Mbus Reg 15C0h bit0 Input Func 0–7F 0BA0 Page 175 H01-41 Mbus Reg 15C0h bit1 Input Func 0–7F...
Page 268 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) H02-63 Term M3-M4 Secondary Function 0–1A7 1B49 Page 183 H02-64 Terminal M3-M4 Logical Operation 0–8 1B4A Page 183 H02-65 Terminal M3-M4 Delay Time 0.0–25.0 1B4B Page 183 H02-66 Term M5-M6 Secondary Function 0–1A7 1B4C Page 183...
Page 269 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) H05-05 Comm Fault Detection Selection 0–1 0429 Page 189 H05-06 Drive Transmit Wait Time 0–65 042A Page 189 H05-09 CE Detection Time 0.0–10.0 0435 Page 189 H05-10 Modbus Register 0025H Unit Sel 0–1 0436 Page 189...
Page 270 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) H07-30 Virtual Analog Input Selection 0–4F 1177 Page 192 H07-31 Virtual Analog Input Gain 100.0 -999.9–999.9 1178 Page 192 H07-32 Virtual Analog Input Bias -999.9–999.9 1179 Page 192 H07-40 Virtual Analog Out Signal Select 0–2 1163 Page 192...
Page 271 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) Depends on L03-02 Stall Prevent Level during Accel 0–150 0490 Page 196 D10-01 L03-03 Stall Prevent Limit during Accel 0–100 0491 Page 196 L03-05 Stall Prevention during RUN 0–2 0493 Page 196 Depends on L03-06 Stall Prevent Level during Run...
Page 272 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) L06-07 Torque Detection Filter Time 0–1000 04E5 Page 201 L06-08 Mechanical Fatigue Detect Select 0–8 0468 Page 201 L06-09 Mech Fatigue Detect Speed Level 110.00 -110.0–110.0 0469 Page 202 L06-10 Mech Fatigue Detect Delay Time 0.0–10.0 046A Page 202...
Page 273 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) n01-20 Voltage Calibration Duration 10–500 1588 Page 208 n02-01 Automatic Freq Regulator Gain 1.00 0.00–10.00 0584 Page 208 n02-02 Automatic Freq Regulator Time 1 0–2000 0585 Page 208 n02-03 Automatic Freq Regulator Time 2 0–2000 0586 Page 208...
Page 274 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) o02-05 Home Mode Freq Ref Entry Mode 0–1 0509 Page 212 o02-09 Region Code 1–2 050D Page 212 o02-10 Motor Power Units 0–1 3125 Page 212 o02-23 External 24V Powerloss Detection 0–1 11F8 Page 212...
Page 275 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) U01-03 Output Current 0042 Page 215 U01-04 Control Method 0043 Page 215 U01-05 Motor Speed 0044 Page 215 U01-06 Output Voltage Reference 0045 Page 215 U01-07 DC Bus Voltage 0046 Page 215 U01-08 Output Power HP/kW...
Page 276 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) U02-04 Output Frequency @ Fault 0083 Page 217 U02-05 Output Current @ Fault 0084 Page 217 U02-06 Motor Speed @ Fault 0085 Page 217 U02-07 Output Voltage @ Fault 0086 Page 217 U02-08 DC Bus Voltage @ Fault 0087...
Page 277 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) U04-04 Cooling Fan Maintenance 007E Page 218 U04-05 Capacitor Maintenance 007C Page 218 U04-06 Precharge Relay Maintenance 07D6 Page 218 U04-07 IGBT Maintenance 07D7 Page 218 U04-08 Heatsink Temperature °C 0068 Page 218 U04-09 LED Check...
Page 278 Modbus Parameter Parameter Name Default Range Units Reference (Hex.) U06-17 Energy Save Coefficient 07D1 Page 220 U06-21 Offset Frequency 07D5 Page 220 U06-26 Feed Forward Contol Output 006C Page 220 U06-31 Torque Detect Monitor 007B Page 220 U06-36 Comm Errors-Host 0720 Page 220 U06-37...
Page 279 Appendix B: Standards Compliance Electromagnetic Compatibility (EMC) Guidelines Compliance Figure B-1: CE Mark The CE mark indicates compliance with European safety and environmental regulations. It is required for engaging in business and commerce in Europe. European standards include the Machinery Directive for machine manufacturers, the Low Voltage Directive for electronics manufacturers, and the EMC guidelines for controlling noise.
Page 280 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 4605-G+/VG+S5, 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 281 Figure B-4: EMC Filter and VFD Installation for CE Compliance IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 281...
Page 282 EMC Filters Install the VFD with the EMC filters listed in Table B-1 and Table B-2 to comply with the EN 61800-3 requirements. Table B-1: EMC Filters – 230 V Class Filter Specifications Mounting Rated Dimensions VFD Model Weight Dimensions Current Filter Model W x H x D (in)
Page 283 Table B-2: EMC Filters - 460V Class Filter Specifications Mounting Rated Dimensions VFD Model Weight Dimensions Current Filter Model W x H x D (in) W1 x H1 (in) lb (kg) [W x H x D (mm)] [W1 x H1 (mm)] 4001 4003 B84143A0010R106...
Page 284 DC Link Chokes for EN 61000-3-2 Compliance Table B-3: 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. IMPULSE•G+/VG+ Series 5 Technical Manual August 2023 Page 284...
Page 285 IMPULSE•G+/VG+ Series 5 Adjustable Frequency/Vector Crane Controls Technical Manual August 2023...

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Columbus McKinnon Magnetek IMPULSE-G+ 5 Series Technical Manual

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2 Installation

3 Wiring

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