Magnetek Impulse 2007-VG+S4, Impulse 2003-G+S4, Impulse 2003-VG+S4, Impulse 2008-G+S4, Impulse 2005-VG+S4 Instruction Manual
...
INSTRUCTION MANUAL
Software #14707.x & 14750.x
Part Number: 144-23910 R6
© Copyright 2017 Magnetek
February 2017
©2017 MAGNETEK
All rights reserved. This notice applies to all copyrighted materials included with this product,
including, but not limited to, this manual and software embodied within the product. This manual is
intended for the sole use of the persons to whom it was provided, and any unauthorized distribution
of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in
whole or in part by any means whatsoever without the expressed written permission of Magnetek.
Parts of this product may be covered by one or more of the following patents: 6,598,859, 6,653,804,
6,956,339, 7,190,146, 7,841,583, 8,401,814, 8,669,724, and 8,686,670.
Product Safety Information
Magnetek, Inc. (Magnetek) offers a broad range of radio remote control products, control products
and adjustable frequency drives, 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). Anyone who uses, operates, maintains, services, installs or owns Magnetek
Products should know, understand and follow the instructions and safety recommendations in this
manual for Magnetek Products.
The recommendations in this manual do not take precedence over any of the following requirements
relating to cranes, hoists lifting devices or other material handling equipment which use or include
Magnetek Products:
• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the
Magnetek Products are used,
• Plant safety rules and procedures of the employers and the owners of the facilities where the
Magnetek Products are being used,
• Regulations issued by the Occupational Health and Safety Administration (OSHA),
• Applicable local, state or federal codes, ordinances, standards and requirements, or
• Safety standards and practices for the industries in which Magnetek Products are used.
This manual does not include or address the specific instructions and safety warnings of these
manufacturers or any of the other requirements listed above. It is the responsibility of the owners,
users and operators of the Magnetek Products to know, understand and follow all of these
requirements. It is the responsibility of the employer to make its employees aware of all of the above
listed requirements and to make certain that all operators are properly trained. No one should use
Magnetek Products prior to becoming familiar with and being trained in these requirements
and the instructions and safety recommendations for this manual.
Product Warranty Information
Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming
of a drive by untrained personnel. A drive should only be programmed by a trained technician who
has read and understands the contents of this manual. Improper programming of a drive can lead to
unexpected, undesirable, or unsafe operation or performance of the drive. This may result in
damage to equipment or personal injury. Company shall not be liable for economic loss, property
damage, or other consequential damages or physical injury sustained by the purchaser or by any
third party as a result of such programming. Company neither assumes nor authorizes any other
person to assume for Company any other liability in connection with the sale or use of this product.
For information on Magnetek’s product warranties by product type, please visit
www.magnetekmh.com.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
i
DANGER, WARNING, CAUTION, and NOTE Statements
WARNING
Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or
performance of the drive.
DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death
or serious injury. This signal word is to be limited to the most extreme situations.
WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
minor or moderate injury. It may also be used to alert against unsafe practices.
NOTE: A NOTE statement is used to notify installation, operation, programming, or
maintenance information that is important, but not hazard-related.
DANGER, WARNING, CAUTION, and Note statements are used throughout this manual to
emphasize important and critical information. You must read these statements to help ensure safety
and to prevent product damage. The statements are defined below.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
ii
Service Information
For questions regarding service or technical information contact:
1.866.MAG.SERV
(1.866.624.7378)
World Headquarters
Magnetek, Inc.
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
1.800.288.8178
EU Market Contact
Magnetek (UK) Ltd.
Unit 3 Bedford Business Centre
Mile Road
Bedford, MK42 9TW UK
Phone: +44.1234.349191
Fax: +44.1234.268955
Magnetek, Inc. has additional satellite locations for Canada and the United States. For more
information, please visit http://www.magnetek.com.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
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IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
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Contents:
Product Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-i
DANGER, WARNING, CAUTION, and NOTE Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-ii
Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-iii
Chapter 1: Introduction
How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Assessing the System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Assessing the Drive Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
IMPULSE®•G+ & VG+ Series 4 General Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
AC Reactor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
S4IF Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
S4I and S4IO Option Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Chapter 2: Installation
IMPULSE®•G+ & VG+ Series 4 System Components And External Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Long Time Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Multiple Drive Installation (Side-by-Side Installation). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Drive Derating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Temperature Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Dimensions for IP00/Open Chassis Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Chapter 3: Wiring
IMPULSE®•G+ & VG+ Series 4 Wiring Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Suggested Circuit Protection Specifications and Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Power Circuit Wiring Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Main Circuit Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Terminal Block Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Insulation Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Interface Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
S4IF DIP Switches and Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Dip Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Sinking/Sourcing Mode Selection for Safe Disable Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Control Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
S4IF Control Circuit Terminal Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Wiring the Encoder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Encoder Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Encoder Wiring Diagrams and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Chapter 4: Getting Started
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Checks Before Powering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Using the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
Keypad LED and Button Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Parameter Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
IMPULSE®•G+ & VG+ Series 4 Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Initialization Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Parameter Access Level (A01-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Control Method Selection (A01-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
X-Press Programming™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Motion (A01-03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Speed Reference (A01-04). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Initialize Parameters (A01-05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Password Entry (A01-06) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
User Parameters (A02-01 through 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Auto-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Standard Auto-Tune (T01-01 = 0) Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Non-Rotational Auto-Tune (T01-01 = 1) Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Terminal Resistance Auto-Tune (T01-01 = 2) Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Non-Rotational 2 Auto-Tune (T01-01 = 4) Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Chapter 5: Programming Advanced Features
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Preset Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Reference Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Sequence/Reference Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Stop Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Decel to Stop (B03-03=0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Coast to Stop (B03-03=1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Decel w/Timer (B03-03=4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Motor Rotation Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Zero-Speed Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Input Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
LO/RE Run Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Acceleration/Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Accel/Decel Time Switching Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Jump Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Quick Stop™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Reverse Plug Simulation™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Micro-Speed™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
End of Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Phantom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Load Sharing/Torque Following - 2 or more mechanically coupled motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Klixon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Hook Height Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Electronic Programmable Limit Switches (EPLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
Lower Limit/Upper Limit Bypass MFDI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Load Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Load Check II™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
V/f Operation (A01-02 = 00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
OLV and FLV Operation (A01-02 = 02 and 03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Load Check II Set Up (C05-01 = 09) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Swift-Lift™ & Ultra-Lift™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Swift-Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Ultra-Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Adaptive Ultra-Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Configuring the Swift-Lift & Ultra-Lift Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Anti-Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
No-Load Brake Hoist (VG+). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
E-Lift (VG+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Digital Input Option Set-up (DI-A3 and S4IO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Weight Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
System Tare and Calibration for Weight Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Setting Up U01-29 to Display Actual Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Weight Measurement Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Slack Cable Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Snap Shaft Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Brake Delay Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Timer Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
Maintenance Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Inching Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Index Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
DC Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Motor Slip Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Torque Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Automatic Speed Regulator (ASR) Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Torque Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61
Speed/Torque Control Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62
S-Curve Acceleration/Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65
Carrier Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66
Hunting Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67
Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Voltage/Frequency Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68
Motor Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73
Test Mode Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-74
Option Card Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Encoder (PG) Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75
Analog Input (AI-A3) Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78
Analog Output (AO-A3) Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-79
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
Digital Output (DO-A3) and S4IO Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80
Profibus-DP Communication Option Card Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82
Ethernet Option Card Set-up (Ethernet IP & Modbus TCP/IP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84
Terminal Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-86
F1 and F2 Keys Function Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-90
Digital Outputs—Alarm/Fault Annunciate (H02-01–03=40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94
Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100
Serial Communication Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-102
Pulse Train Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-104
Protection Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-105
Power Loss Ride Thru . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
Stall Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107
Speed Agree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-109
Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-111
Torque Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-112
Hardware Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-115
Automatic Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-118
Fault Latch Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-120
Operator Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
Monitor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
Keypad Key Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-124
Maintenance History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127
Copy Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
Monitor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-131
Chapter 6: Troubleshooting
Troubleshooting the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Troubleshooting Encoder Related Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Fault Code: DEV– Speed Deviation Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Fault Code: PGO-X-S/PGO-X-H–Pulse Generator Signal Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Fault Code: BE1–Rollback Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Fault Code: BE2–Torque Proving Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Fault Code: BE3–Brake Release Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Alarm Code: BE6–Brake Proving Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Alarm Code: BE8–Brake Slipping Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Fault Code: OC–Over Current Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Fault Display and Corrective Actions at Auto-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Troubleshooting Option Card Related Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Drive-Side Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Copy Function Related Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Tasks, Errors, and Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
Power Section Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Power Off Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
S4IF Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Appendix A: Parameter Listing
IMPULSE®•G+ & VG+ Series 4 Parameter Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
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IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
Chapter 1
Introduction
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IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-2
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.
Do not check signals during operation.
Do not connect the main output terminals (U/T1, V/T2, W/T3) to the incoming, three-phase AC
source.
Before executing a rotational Auto-Tuning, ensure that the motor is disconnected from the drive
train and the electric brake is released. If the electric brake cannot be released, you must ensure
that the brake is disengaged for the entire tuning process.
Read and understand this manual before installing, operating, or servicing this drive. All
warnings, cautions, and instructions must be followed. All activity must be performed by qualified
personnel. The drive must be installed according to this manual and local codes.
Do not connect or disconnect wiring while the power is on. Do not remove covers or touch circuit
boards while the power is on. Do not remove or insert the digital operator while power is on.
Before servicing, disconnect all power to the equipment. The internal capacitor remains charged
even after the power supply is turned off. The charge indicator LED will extinguish when the DC
bus voltage is below 50 VDC. To prevent electric shock, wait at least five minutes after all
indicators are OFF and measure DC bus voltage to confirm safe level.
Do not perform a withstand voltage test on any part of the unit. This equipment uses sensitive
devices and may be damaged by high voltage.
The drive is suitable for circuits capable of delivering not more than 100,000 RMS symmetrical
Amperes. Install adequate branch circuit short circuit protection per applicable codes. Failure to
do so may result in equipment damage and/or personal injury.
Do not connect unapproved LC or RC interference suppression filters, capacitors, or overvoltage
protection devices to the output of the drive. These devices may generate peak currents that
exceed drive specifications.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-3
How to Use This Manual
This manual provides technical information on IMPULSE®•G+ and VG+ Series 4 parameter settings,
drive functions, troubleshooting, and installation details. Use this manual to expand drive
functionality and to take advantage of higher performance features. This manual is available for
download on the Magnetek Material Handling document center website at www.magnetekmh.com.
The IMPULSE
®
•G+ and VG+ Series 4 drives share a common power section, and similar
parameters. The parameters and performance differ because the VG+ drives includes a PG-X3
encoder feedback card allowing the drive to perform Flux Vector control of the motor. The G+ drives
operate in V/f or Open Loop Vector control methods, appropriate for traverse or standard hoist
motions. The VG+ drives are typically applied to the non-mechanical load brake hoist motion, and
can be applied to traverse motions where torque control or a wide speed control range is required.
Many IMPULSE
®
•G+ and VG+ Series 4 parameter functions are common between the two drive
classes. The functions that differ are noted with a “Model” column; this column designates which
parameters are available for a given function. Functions may also be control method dependent;
these differences are noted in the function and parameter details. Table 1-1 below notes which
drives can operate in a particular control method.
Table 1-1: Control Methods by Model
Drive Model
G+
G+
VG+ Flux Vector (3) 1500:1
Control Method
(A01-02)
V/f (0) 40:1
Open Loop Vector
(2)
Speed Control
Range
200:1
Motion (A01-03)
Traverse (0)
Standard Hoist (1)
Traverse (0)
Standard Hoist (1)
Traverse (0)
NLB Hoist (2)
The instructions in the following chapters apply to most IMPULSE®•G+ & VG+ Series 4 crane, hoist,
and monorail applications. However, carefully evaluate each specific situation and ensure that the
National Electric Code (NEC) codes and local wiring practices are followed.
These chapters explain how to install the IMPULSE
components that it interconnects. It explains how to: assess the drive’s environment, mount the
drive, and wire the drive circuits. It is important to develop a “plan of attack” for both the mounting
and wiring since each task has an effect on the other one. IMPULSE
Practices is included to provide assistance and reference.
NOTE: If the IMPULSE
®
•G+ & VG+ Series 4 is part of a Magnetek motor control panel, reference
the control drawings, disregard this chapter, and turn to Chapter 4.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-4
®
•G+ & VG+ Series 4 and, to some extent, the
®
•G+ & VG+ Series 4 Wiring
Introduction
Assessing the System Requirements
It is important to know how the drive will be utilized before working on installation and wiring. 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, No Load Brake (NLB) Hoist
• Power source voltage, number of phases, and kVA rating
• Power source location
•Wire size
• Grounding location and method
• Control wiring sources - i.e. cab, pendant, radio
Assessing the Drive Environment
When choosing a location for IMPULSE®•G+ & VG+ Series 4, perform the following steps:
1. Ensure that a three-phase 200 to 240 VAC 50/60 Hz power supply is available for a 230 VAC-
rated drive, a three-phase 380 to 480 VAC 50/60 Hz power supply is available for a 460 VACrated drive, and a 500 to 600 VAC 50/60 Hz power supply is available for a 575 VAC-rated drive.
2. Ensure the encoder is supplied with +5 VDC or 12 VDC.
3. If the RMS encoder current requirement is greater than 200 mA, provide an auxiliary power
supply to the encoder.
4. Ensure that the drive-to-motor wiring distance is less than 150 ft. unless appropriate reactors,
filters, and/or inverter duty motor is used.
5. Ensure that the drive circuit wiring is protected or isolated from:
• Ambient temperatures outside the range of +14°F to +140°F (-10°C to +60°C) at 2 kHz
carrier frequency.
• Rain or moisture
• Corrosive gases or liquids
• Direct sunlight
• Severe mechanical vibration
6. Ensure that the drive is housed in an appropriate NEMA-rated enclosure.
7. For severe-duty applications (long lifts, for example) or with 75-HP-or-greater motors, ensure
that the drive control system (including dynamic braking resistors) is adequately cooled, even
though the ambient temperature limit is not exceeded. For more information, contact Magnetek.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-5
IMPULSE®•G+ & VG+ Series 4 General Specifications
Table 1-2: Specification Values and Information - Heavy Duty
230 V
Model
(-G+/
VG+S4)
2003
2005
2007 6.9 2.6 4004 4.8 3.7 5004 4.1 4.1
2008
2011 11.0 4.2 4007 7.2 5.5 5009 9.8 9.8
2014 14.0 5.3 4009 9.2 7.0 5012 12.5 12.5
2017 17.5 6.7 4014 14.8 11.3 5017 17.0 17.0
2025 25.0 9.5 4018 18.0 13.7 5022 22.0 22.0
2033 33.0 12.6 4024 24.0 18.3 5027 27.0 27.0
2047 47.0 17.9 4031 31.0 24.0 5032 32.0 32.0
2060 60.0 23.0 4039 39.0 30.0 5041 41.0 41.0
2075 75.0 29.0 4045 45.0 34.0 5052 52.0 52.0
2085 85.0 32.0 4060 60.0 48.0 5062 62.0 62.0
2115 115 44.0 4075 75.0 57.0 5077 77.0 77.0
2145 145 55.0 4091 91.0 69.0 5099 99.0 99.0
2180 180 69.0 4112 112 85.0 5130 130 129
2215 215 82.0 4150 150 114 5172 172 171
2283 283 108 4180 180 137 5200 200 199
2346 346 132 4216 216 165 -- -- --
2415 415 158 4260 260 198 -- -- --
-- -- -- 4304 304 232 -- -- --
-- -- -- 4370 370 282 -- -- --
-- -- -- 4450 450 343 -- -- --
-- -- -- 4605 605 461 -- -- --
-- -- -- 4810 810 617 -- -- --
-- -- -- 41090 1090 831 -- -- --
Rated
Output
Current
(A)
3.2 1.2 4001 1.8 1.4 5001 1.7 1.7
5.0 1.9 4003 3.4 2.6 5003 3.5 3.5
8.0 3.0 4005 5.5 4.2 5006 6.3 6.3
Output
Capacity
(kVA)
Model
(-G+/
VG+S4)
460 V 575 V
Rated
Output
Current
(A)
Output
Capacity
(kVA)
Model
(-G+/
VG+S4)
Rated
Output
Current
(A)
Output
Capacity
(kVA)
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-6
Table 1-3: Specifications for 230 V, 460 V, and 575 V
Specification Specification Value and Information for All Models
Certification UL, cUL, CSA, CE, RoHS
Crane Duty Classification Rated for CMAA Crane Duty Class A - F only (or equivalent)
Rated input power supply volts
& freq
Control Voltage 120 VAC (50/60 Hz) standard
Allowable input and control
voltage fluctuation
Allowable input frequency
fluctuation
Allowable control frequency
fluctuation
Control method Fully digital, V/f, open loop vector, or flux vector control; sine-wave, pulse-
Maximum output voltage (VAC) 3-phase 200 to 240 VDC (proportional to input voltage)
Rated frequency (Hz) 150 Hz standard (400 Hz optional, consult factory and equipment
Output speed control range FLV: 1500:1; OLV: 200:1; V/f: 40:1
Output frequency accuracy 0.01%—with digital reference command
Frequency reference resolution Digital: 0.01 Hz; analog: 0.03 Hz (at 60 Hz)
Output frequency resolution 0.01 Hz
Overload capacity 150% of drive rated load for 1 min
Remote frequency reference
sources
Accel/decel times 0.1 to 6000.0 sec—4 sets; 8 parameters are independently adjustable
Braking torque 150% or more with dynamic braking
DC Link Choke Models 2085 to 2415 and 4045 to 41090 come with a built-in DC link choke.
Internal Braking Transistor Models 2003 to 2115, 4001 to 4060, and 5001 to 5041 come with an internal
Motor overload protection UL recognized electronic thermal overload relay; field-programmable
Overcurrent protection level
(OC1)
Circuit protection Ground fault and blown-fuse protection
Overvoltage protection level 230 VAC class: Stops when DC bus voltage exceeds approx. 410 VDC
Undervoltage protection level 230 VAC class: Stops when DC bus voltage falls below approx. 190 VDC
* 2kHz carrier frequency
** Maximum rated temperature of 65°C at the drive chassis with factory approved air handling system
3-phase 200 to 240 VAC 50/60 Hz for a 230 VAC-rated drive
3-phase 380 to 480 VAC 50/60 Hz for a 460 VAC-rated drive
3-phase 500 to 600 VAC 50/60 Hz for a 575 VAC-rated drive
42–48 VAC (50/60 Hz)
24 VAC (50/60 Hz)
24 VDC
+10% or -15% of nominal
±5% of nominal
±3 Hz of nominal
width-modulated
3-phase 380 to 480 VDC (proportional to input voltage)
3-phase 500 to 600 VDC (proportional to input voltage)
manufacturer)
0.1%—with analog reference command; 10 bits/10 V
0–10 VDC (20k); 4–20 mA (250); ±10 VDC serial (RS-485)
braking transistor (B1 and B2 terminals).
200% of drive rated current
460 VAC class: Stops when DC bus voltage exceeds approx. 820 VDC
575 VAC class: Stops when DC bus voltage exceeds approx. 1040 VDC
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
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-7
Specification Specification Value and Information for All Models
Heatsink overtemperature Thermostat trips at 105°C (221°F)
Torque limit selection Separate functions for FORWARD, REVERSE, REGEN; all selectable from
0–300%
Stall prevention Separate functions for accel, decel, at-speed, and constant horsepower
region
Other protection features VG+: Speed deviation, overspeed, mechanical brake failure, lost output
phase, failed-oscillator, PG-disconnect, roll-back detection, micro controller
watchdog, internal braking transistor failure, torque output limit, motor
overcurrent, inverter overcurrent, input phase loss.
G+: Lost output phase, micro-controller watchdog, internal braking resistor
failure, motor overcurrent, inverter overcurrent, input phase loss.
DC bus voltage indication Charge LED is on until DC bus voltage drops below 50 VDC
Location Indoors; requires protection from moisture, corrosive gases, and liquids
Ambient operating temperature -10° to 60°C (14° to 140°F)*
-10° to 65°C (14° to 149°F)**
Storage temperature -20°C to +70°C (-4°F to 158°F)
Humidity 95% relative humidity or less and free of condensation
Vibration
Elevation 1000 m or lower, up to 3000 m with derating.
Orientation Install the drive vertically to maintain maximum cooling effects.
* 2kHz carrier frequency
** Maximum rated temperature of 65°C at the drive chassis with factory approved air handling system
10 to 20 Hz at 9.8 m/s
20 to 55 Hz at 5.9 m/s
5077) or
20 to 55 Hz at 2.0 m/s
5200)
2
2
(Models 2003 to 2180, 4001 to 4150, and 5001 to
2
(Models 2215 to 2415, 4180 to 4605, and 5099 to
AC Reactor Specifications
Reactors, both as input (line) and output (load) devices, protect adjustable frequency drives, motors,
and other load devices against excessive voltage and current.
The following guidelines may help determine input and output reactor requirements:
• The following tables are only a guideline. The motor FLA should not exceed the reactor FLA.
• Install an input reactor if the power source is greater than 500 kVA.
• Install an output reactor if the distance between the drive and the motor exceeds 150 feet.
• Install an output reactor if a device, such as a power limit switch, is used to disconnect the motor
from the drive. Use a power limit switch early break circuit to fault the drive.
• Install one output reactor per drive for a multiple-drive arrangement requiring reactor protection.
• For a multiple drive arrangement, an input reactor for each drive is recommended for optimal
protection. However, if the drives are within two drive sizes of each other, a single input reactor
can be used. The reactor must be rated at amperage equal to or greater than the sum of the
amperage for all the drives.
• Reactors are most effective when the reactor current rating approaches the drive current rating.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-8
Table 1-4: 230 V Class
Model Number 230 V Part Number Maximum Amps of Reactor
2003-G+/VG+S4 REA230-1 4
2005-G+/VG+S4 REA230-1 4
2007-G+/VG+S4 REA230-2 8
2008-G+/VG+S4 REA230-2 8
2011-G+/VG+S4 REA230-3 12
2014-G+/VG+S4 REA230-3 12
2017-G+/VG+S4 REA230-5 18
2025-G+/VG+S4 REA230-7.5 25
2033-G+/VG+S4 REA230-10 35
2047-G+/VG+S4 REA230-15 45
2060-G+/VG+S4 REA230-20 55
2075-G+/VG+S4 REA230-25 80
2085-G+/VG+S4 REA230-30 80
2115-G+/VG+S4 REA230-40 100
2145-G+/VG+S4 REA230-50 130
2180-G+/VG+S4 REA230-60 160
2215-G+/VG+S4 REA230-75 200
2283-G+/VG+S4 REA230-100 250
2346-G+/VG+S4 REA230-125 320
2415-G+/VG+S4 REA230-150 400
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
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Table 1-5: 460 V Class
Model Number 460 V Part Number Maximum Amps of Reactor
4001-G+/VG+S4 REA460-1 2
4003-G+/VG+S4 REA460-2 4
4004-G+/VG+S4 REA460-3 6
4005-G+/VG+S4 REA460-5 8
4007-G+/VG+S4 REA460-5 8
4009-G+/VG+S4 REA460-5 8
4014-G+/VG+S4 REA460-7.5 12
4018-G+/VG+S4 REA460-10 18
4024-G+/VG+S4 REA460-15 25
4031-G+/VG+S4 REA460-20 35
4039-G+/VG+S4 REA460-25 35
4045-G+/VG+S4 REA460-30 45
4060-G+/VG+S4 REA460-40 55
4075-G+/VG+S4 REA460-50 80
4091-G+/VG+S4 REA460-60 80
4112-G+/VG+S4 REA460-75 100
4150-G+/VG+S4 REA460-100 130
4180-G+/VG+S4 REA460-150 200
4216-G+/VG+S4 REA460-150 200
4260-G+/VG+S4 REA460-200 250
4304-G+/VG+S4 REA460-250 320
4370-G+/VG+S4 REA460-300 400
4450-G+/VG+S4 REA460-400 500
4605-G+/VG+S4 REA460-500 600
4810-G+/VG+S4 Consult Factory Consult Factory
41090-G+/VG+S4 Consult Factory Consult Factory
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
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Table 1-6: 575 V Class
Model Number 600 V Part Number Maximum Amps of Reactor
5001-G+/VG+S4 REA575-1 2
5003-G+/VG+S4 REA575-2 4
5004-G+/VG+S4 REA575-3 4
5006-G+/VG+S4 REA575-5 8
5009-G+/VG+S4 REA575-10 12
5012-G+/VG+S4 REA575-10 12
5017-G+/VG+S4 REA575-15 18
5022-G+/VG+S4 REA575-20 & 25 25
5027-G+/VG+S4 REA575-30 35
5032-G+/VG+S4 REA575-30 35
5041-G+/VG+S4 REA575-40 45
5052-G+/VG+S4 REA575-50 55
5062-G+/VG+S4 REA575-60 80
5077-G+/VG+S4 REA575-75 80
5099-G+/VG+S4 REA575-100 100
5130-G+/VG+S4 REA575-150 160
5172-G+/VG+S4 REA575-200 200
5200-G+/VG+S4 REA575-200 200
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-11
S4IF Interface Specifications
IMPULSE®•G+ & VG+ Series 4 is designed to interface with user input and output devices through
the S4IF interface board. This eliminates the need for an additional interface relay or isolation
circuitry. The S4IF comes in 24 VDC, 24 VAC (50/60 Hz), 42 to 48 VAC (50/60 Hz), and 120 VAC
(50/60 Hz) options.
The S4IF has eight optically isolated input terminals which can be used to connect the user input
device to the drive. The eight terminals are multi-function terminals, and are used for speed control
and other controls.
The drive has four 250 VAC, 1.0 Amp relays for output devices. It includes three programmable
multi-function output terminals, and a fault output terminal.
NOTE: The 250 VAC relays must be derated to 48 VAC to comply with CE.
Table 1-7: S4IF Ratings
S4IF Model
S1-S8
Voltage Frequency
S4IF-120A60* 120 VAC 50/60 Hz
S4IF-48A60 42–48 VAC 50/60 Hz
S4IF-24A60 24 VAC 50/60 Hz
S4IF-24D00 24 VDC --
* Not certified for CE compliance.
S4I and S4IO Option Specifications
IMPULSE®•G+ & VG+ Series 4 is compatible with AC digital input (S4I) and AC digital input/output
(S4IO) options. The options expand the I/O capability of the drives, without the need for interface
relays or isolation circuitry.
The S4I has four optically isolated input terminals. The S4IO has four optically isolated input
terminals and four dry contact form A relays.
Table 1-8: S4I Ratings
S4I Model
Voltage Frequency
S4I-120A60* 120 VAC 50/60 Hz
S4I-48A60 42–48 VAC 50/60 Hz
S4I-24A60 24 VAC 50/60 Hz
I1-I4
* Not certified for CE compliance.
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
1-12
Table 1-9: S4IO Ratings
I1-I4 O1-O6
S4IO Model
Voltage Frequency Voltage (max)
S4IO-120A60* 120 VAC 50/60 Hz
S4IO-24A60 24 VAC 50/60 Hz
* Not certified for CE compliance.
250 VAC
(48VAC for CE)/
30 VDC
Current
(max)
1.0 AS4IO-48A60 42–48 VAC 50/60 Hz
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Chapter 2
Installation
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IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
2-2
This chapter explains the following:
WARNING
•When preparing to mount the IMPULSE®•G+ & VG+ Series 4 drive, lift it by its base. Never lift
the drive by the front cover, as doing so may cause drive damage or personal injury.
•Mount the drive on nonflammable material.
•The IMPULSE
®
•G+ & VG+ Series 4 drive generates heat. For the most effective cooling
possible, mount it vertically. For more details, refer to the “IMPULSE
®
•G+ & VG+ Series 4
Dimensions/Heat Loss-Open Chassis” in this chapter.
•When mounting units in an enclosure, install a fan or other cooling device to keep the
enclosure temperature below 65°C (149°F)*.
Failure to observe these warnings may result in equipment damage.
1. Choosing a location
2. IMPULSE
®
•G+ & VG+ Series 4 components and external devices
3. Drive environment
4. Drive installation
In addition, this section will cover information on the components that interconnect with
IMPULSE
®
•G+ & VG+ Series 4.
Choosing a Location
Be sure that the drive is mounted in a location protected against the following conditions:
• Extreme cold and heat. Use only within the ambient temperature range:
-10°C to +60°C (+14°F to 140°F)*
• Direct sunlight (not for use outdoors)
• Rain, moisture
• High humidity
• Oil sprays, splashes
• Salt spray
• Dust or metallic particles in the air
• Corrosive gases (e.g. sulfurized gas or liquids)
• Radioactive substances
• Combustibles (e.g. thinner, solvents, etc.)
• Physical shock, vibration
• Magnetic noise (e.g. welding machines, power devices, etc.)
* 2 kHz carrier frequency
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
2-3
IMPULSE®•G+ & VG+ Series 4 System Components And
External Devices
Standard IMPULSE®•VG+ Series 4 Drive Components
• PG-X3 Line Driver Encoder Card
Optional Drive Components
• DI-A3 Digital DC Input Card
• DO-A3 Digital Output Card
• AI-A3 Analog Input Card
• AO-A3 Analog Output Card
• S4I-xxxA60 Control Digital AC Input Card
• S4IO-xxxA60 Control Digital AC Input/Output Card
• PS-A10L 24 VDC Control Power Unit for 230 V models
• PS-A10H 24 VDC Control Power Unit for 460 V and 575 V models
• PG-B3 Open Collector Encoder Card
• SI-EN3 EtherNet/IP
• SI-EM3 Modbus TCP/IP
• SI-EP3 PROFINET
• SI-P3 PROFIBUS-DP
As-Required Drive Components
• AC reactor - line or load
• DC bus choke
• External dynamic braking resistor(s)
• External dynamic braking unit
Required External Devices
• Motor
• User input device (pendant, joystick, PC, PLC, radio, or infrared control)
• External circuit protection devices (fuses or circuit breakers) (See “Suggested Circuit Protection
Specifications and Wire Size” in Chapter 3).
• R-C surge suppressors on contactor coils
IMPULSE®•G+ & VG+ Series 4 Instruction Manual - February 2017
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