Electromotive Systems IMPULSE•VG+ Series 2 crane control Instruction manual

©1999 ELECTROMOTIVE SYSTEMS, INC.

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

ELECTROMOTIVE SYSTEMS, INC.

DANGER, WARNING, CAUTION, and NOTE Statements

DANGER, WARNING, CAUTION, and Note statements are used throughout this manual to emphasize important and critical information. You must read these statements to help ensure safety and to prevent product damage. The statements are defined below.

DA N G E R

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.

WA R N I N G

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

C AU T I O N

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 people of installation, operation, programming, or maintenance information that is important, but not hazard-related.

This page intentionally left blank.

Contents

Welcome! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Identifying Your Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Chapter 1: Introduction

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Assessing the System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Assessing the Drive Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

IMPULSE•VG+ Series 2 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

DBU & CDBR Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

DBU Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

External DBU Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Minimum Resistor Ohmic Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

IMPULSE•VG+ Series 2 External Dynamic Braking Unit—

Specifications & Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

AC Reactor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Interface Cards Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Interface Card Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Chapter 2: Installation

IMPULSE•VG+ Series 2 System Components And External Devices . . . . . . . . . . . . . . . . . . 2-4

Long Time Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Installing the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

IMPULSE•VG+ Series 2 Dimensions/Heat Loss—Open Chassis . . . . . . . . . . . . . . . . . . . . . 2-9

IMPULSE•VG+ Series 2 Dimensions/Heat Loss—Open Chassis . . . . . . . . . . . . . . . . . . . . 2-10

Chapter 3: Wiring

IMPULSE•VG+ Series 2 Wiring Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

IMPULSE•VG+ Series 2 Standard Connection Diagram . . . . . . . . . . . . . . . . . . . 3-5

Suggested Circuit Protection Specifications and Wire Size . . . . . . . . . . . . . . . . . . 3-6

Power Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Installation/Wiring of CDBR Braking Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

IMPULSE•VG+ Series 2 Instruction Manual – 5/24/99 Software #14908 i

Power Circuit Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Wiring the Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Control Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Additional Input Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Control Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Control Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Control Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Wiring the Encoder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Encoder Circuit Wiring Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Encoder Wiring Diagrams and Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36

Suggested Circuit Protection Specifications and Wire Size . . . . . . . . . . . . . . . . 3-38

Chapter 4: Programming Basic Features

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Checks Before Powering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Using the Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Keypad LED and Button Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Parameter Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Initialization Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Auto-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Chapter 5: Programming Advanced Features

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Preset Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Reference Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Sequence/Reference Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Trim Control Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Acceleration/Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Accel/Decel Time Switching Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Torque Limit Accel/Decel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

IMPULSE•VG+ Series 2 Instruction Manual –5/24/99 Software #14908 ii

Phase Loss Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Jump Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Quick Stop™/Reverse Plug Simulation™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Micro-Positioning Control™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Travel Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

Zero Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Load Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27

Ultra-Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Torque Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

No-Load Brake Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

Optional Digital Input Set-up (G5IN4 Digital Multi-Function Inputs) . . . . . . . . . . . . . . . . . 5-40

Weight Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

Setup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Slack Cable Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

DC Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

Automatic Slip Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Automatic Speed Regulator (ASR) Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Torque Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

Speed/Torque Control Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54

Droop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Dwell Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

S-Curve Acceleration/Deceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

Carrier Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59

Factory Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60

Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

Voltage/Frequency Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-61

Motor Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-63

Motor 2 Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Motor 2 Voltage/Frequency Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-64

Motor 2 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-65

IMPULSE•VG+ Series 2 Instruction Manual – 5/24/99 Software #14908 iii

Option Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

Encoder (PG) Option Set-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-66

AI-14 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67

Digital Input Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-68

Analog Output Option Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-69

DO-02 Digital Output Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70

DO-08 Digital Output Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71

PO-36F Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-72

Terminal Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-73

Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-76

Digital Outputs—Fault Annunciate (H2-01~03=40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78

External Fault Response Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-80

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-81

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-82

Serial Communication Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83

Protection Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

Motor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-84

Stall Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85

Reference Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

Torque Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89

Hardware Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-92

Automatic Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93

Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-94

Operator Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

Monitor Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-95

Keypad Key Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97

Clear History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-100

Monitor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101

IMPULSE•VG+ Series 2 Instruction Manual –5/24/99 Software #14908 iv

Chapter 6: Troubleshooting IMPULSE•VG+ Series 2

Troubleshooting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Motor Faults and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Drive Faults and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Fault Display and Corrective Actions at Auto-tuning . . . . . . . . . . . . . . . . . . . . . . 6-12

Troubleshooting CDBR Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Power Section Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Power Off Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Braking Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Appendix A: Servicing IMPULSE•VG+ Series 2

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

Service Policy For Small Drives, DBUs, and Other Electrical Components . . . . . . . . . . . . A-3

Service Policy for Large Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4

Electromotive Systems Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

IMPULSE•VG+ Series 2 Parameter Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7

IMPULSE•VG+ Series 2 Instruction Manual – 5/24/99 Software #14908 v

This page intentionally left blank

Welcome!

IMPULSE•VG+ Series 2 represents the second generation of our high-performance flux vector crane controls. It goes far beyond the scalar (voltage and frequency control) drive designs by having

true torque-control capabilities. The IMPULSE•VG+ Series 2, which is designed for a closed-loop system, is ideal for hoists without mechanical load brakes and for very high-performance traverse applications.

Incorporating a pulse-width-modulated (PWM), flux vector design, IMPULSE•VG+ Series 2 generates the optimum current waveform, which gives you impressive torque and speed motor control. The drive offers a 1000:1 speed range — compared to a 3:1 range for two-speed motors and a 10:1 range for wound-rotor motors.

Here’s a sample of IMPULSE•VG+ Series 2’s special features and how they can help you improve your overhead material handling performance:

• Distinct speed control (up to five speeds) as well as infinitely variable speed control are provided; you can use pendant pushbutton stations, infrared or radio controls, or joysticks.

• An English, plain-language liquid crystal display (2 lines, 16 characters per line) makes programming, troubleshooting, and operating the drive easy.

• Built-in Serial Communication (9600-baud modbus) provides reliable digital linkage among the various crane system peripherals, including our line of PulseStar™ Remote Crane Controls.

• Micro-Positioning Control™ is used to place loads with a high degree of precision, eliminating the need to jog or plug your motors.

• A compact circuit design gives the drive a small footprint.

• Ultra-Lift™ capabilities enhance productivity by allowing the overspeeding of any load less than full load.

• Safe Operating Windows™ prevents you from programming the drive with unsafe parameters.

• Automatic Keypad Lockout™ and a snap-in, removable keypad helps you limit programming access and reduce the possibility of programming errors.

• Load Check™ prevents you from overstressing equipment by attempting to lift a load beyond the capacity of the crane or hoist.

• Weight Measurement enables you to weigh a load with an accuracy of ±5 percent of full load.

• Phase Loss Detection causes the drive to fault and commands the electric brake to set if an input or output phase loss occurs.

• Quick Stop™ ensures a rapid deceleration to stop once a drive RUN command is removed, reducing the possibility of a crane collision.

• Reverse Plug Simulation™ allows you to change the direction of travel (motor’s phase sequence) very rapidly before the electric brake can be set.

• Flash ROM stores the drive system’s last four fault occurrences in the drive’s memory—even after power-down—for diagnostic purposes.

IMPULSE•VG+ Series 2 Instruction Manual - 5/24/99 Software #14909 v

• Slack Cable Detection identifies slack cable conditions and adjusts outputs to immediately stop lowering.

• Load Float Start & Stop, with the crane fully at rest (without electric brakes set), allows the precise placement of critical loads without rollback or delays because of electric brake operation.

• Motor Changeover Capability allows you to use one inverter for two motors (e.g., main and auxiliary hoists) with different motor characteristics.

• A 120V Control Voltage Interface Card gives you direct access to a 120V user input device (e.g., pendant) without adding electromechanical components.

• Elapsed Time Counter (with fault history) indicates actual operation time, total power-up time, and the elapsed time between fault occurrences.

Identifying Your Drive

If you ever have to contact Electromotive Systems about your drive, first determine the model and serial numbers of your drive by looking at the nameplate shown below.

IMPULSE

ELECTROMOTIVE SYSTEMS, INC.

MILWAUKEE, WISCONSIN

SERIAL NO.:

MODEL NO.:

A.C. INPUT

VOLTS: PHASE: 3

AMPS: HZ: 50/60

This nameplate is located on the side of the drive nearest to the keypad.

A.C. OUTPUT

VOLTS: PHASE: 3

AMPS: HZ: 0-400

H.P.:

1263

IMPULSE•VG+ Series 2 Instruction Manual - 5/24/99 Software #14909 vi

c h a p t e r

1

Introduction


WA R N I N G

• Do not touch any circuitry components while the main AC power is on. In addition, you must wait until the red “CHARGE” LED is out before performing any service on that unit.

(As you look at the face of the circuitry, the “CHARGE” LED is located in the lower right corner of the board.) It may take as long as 10 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 (T1, T2, T3) to the incoming, three-phase AC source.

• Do not connect the control board terminals, which are the 27 two-tiered terminals, directly to the 120VAC user input device.

• Before executing Built-In 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.

The instructions in the next three chapters apply to most IMPULSE•VG+ Series 2 crane, hoist, and monorail applications. However, you need to carefully evaluate your specific situation and ensure that you follow NEC codes and your local wiring practices.

These chapers tell you how to install IMPULSE•VG+ Series 2 and, to some extent, the components that it interconnects. It explains how to: assess the drive’s environment, mount the drive, and wire the drive circuits. It’s important to develop a “plan of attack” for both the mounting and wiring since each task has an effect on the other one. To assist you, “IMPULSE•VG+ Series 2 Wiring Practices” is included.

NOTE: If your IMPULSE•VG+ Series 2 is part of an Electromotive Systems, pre-engineered

TCONTROLS

®

motor control panel, disregard this chapter and turn to Chapter 4.

IMPULSE•VG+ Series 2 Instruction Manual – 3/17/99 Software #14909

1-3

Introduction

Assessing the System Requirements

You must know how you’re going to use the drive before you start installation and wiring. You will need to know your requirements for the following components:

• Speed control method(s)

• Braking method(s)

• Power source voltage, number of phases, and kVA rating

• Power source location

• Wire size

• Grounding location and method

Assessing the Drive Environment

When you choose a location for IMPULSE•VG+ Series 2, perform the following steps:

1. Ensure that a 220V or 230V (-15% to +10%) three-phase power source is available for a 230Vrated drive, and that a 380V, 400V, 415V, 440V, or 460V (-15% to +10%) three-phase power source is available for a 460V-rated drive, and that a 500V, 575V, 600V (-15% to +10%) power source is available for a 575V Drive.

2. Ensure the encoder is supplied with +12VDC.

3. If the amperage 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 250 ft. unless appropriate reactors and/or filters are used.

5. If required, install reactors.

When connecting a drive (230V/460V/575V, Model 2033-FVG+/4034-FVG+/FVG+5032V and smaller) to a large-capacity power supply transformer (500kVA or greater or more than 10 times the inverter kVA rating), or when switching a phase-advancing capacitor, excessive peak current can flow through the input power supply circuit. To prevent damage to the rectifier section in such cases, install a DC reactor between drive Terminals 1 and 2, or an AC reactor on the input side. Installing reactors also improves the power factor on the power supply side.

6. Ensure that the encoder wiring is less than 300 feet, unless fiber optic cables are used.

7. Ensure that the encoder wiring is isolated from the power wiring.

8. Ensure that the encoder wiring shield is grounded at only one end (PG-X2 TA3).

9. Ensure that the drive circuit wiring is protected or isolated from:

• Ambient temperatures outside the range of -14° F to +104° F (-10° C to +40° C). (Consult

Electromotive Systems if you must exceed this temperature range.)

• Rain or moisture

• Corrosive gases or liquids

• Direct sunlight

• Severe mechanical vibration

10. Ensure that the drive is housed in an appropriate NEMA-rated enclosure.


1-4

11. For severe-duty applications (for example—long lifts) or with 75-Hp-or-greater motors, ensure that the drive control system is adequately cooled, even though the ambient temperature limit is not exceeded. For more information, contact Electromotive Systems.


1-5

IMPULSE•VG+ Series 2 General Specifications

230V Class

Specification Specification Values and Information for Each 230V-Class Model (####-FVG+)

Rated current (A)

Capacity (kVA)

6

2.3

8

3.0

11

4.2

17.5

6.7

25

9.5

33

13

54

19

68

24

80

30

130

50

160

61

224

85

300

110

460V Class


Rated current (A)

Capacity

(kVA)

1.9

3.6

5.1

8.5

11.7

14.8

21 28.6

34

1.4

2.6

3.7

6.1

8.4

11 16 21 26

41

31

52 65

40 50

80 96 128 165 224 302 450 605

61 73 98 130 170 230 340 460

575V Class


Rated current

(A)

Capacity

(kVA)

3.5

2

4.41

3

6.3

5

9.8

7.5

12.5

10

17

15

22

20

27

25

32

30

41

40

52

50

62

60

77

75

99

100

130

125

172

150

200

200

230V, 460V and 575VClasses

Specification

Certification

Rated input power supply volts & freq

Allowable input voltage fluctuation

Allowable input frequency fluctuation

Control method

Maximum output voltage (VA

Rated frequency (Hz)

Output speed control range

Output frequency accuracy

Frequency reference resolution

Output frequency resolution

Overload capacity

Remote frequency reference sources

Accel/decel times

Specification Value and Information for All Models

UL, CUL, CSA

3-phase 200/400, 208/415, 220/440, or 230/460 or 500-600VAC; 50 or 60 Hz

+10% or -15% of nominal

±5% of nominal

Fully digital, flux vector control; sine-wave, pulse-width–modulated

Max output voltage 3-phase, 200/308/220/230V; 380/400/415/440/460V; 500/575/600V

(proportional to input voltage.

Up to twice motor nameplate RPM (Ultra-Lift) 120 Hz max

1000:1

.01%—with digital reference command, -10° to 40° C;

.1%—with analog reference command; 10 bits/10V; 25° C ±10° C

Digital: .01 Hz; analog: .03 Hz (at 60 Hz)

.01 Hz

150% of rated load for 1 min

0–10VDC (20k

Ω

); 4–20mA (250

Ω

); ±10VDC (optional); serial (optional)

0.1 to 25.5 sec—2 sets; 4 parameters are independently adjustable


1-6

Specification

Braking torque

Motor overload protection

Overcurrent protection level (OC1)

Circuit protection

Overvoltage protection level

Undervoltage protection level

Heatsink overtemperature

Torque limit selection

Stall prevention

Other protection features

DC bus voltage indication

Location

Ambient operating temperature

Storage temperature

Humidity

Vibration

Elevation

Specification Value and Information for All Models

Approximately 120% if motor and inverter are sized 1:1; 150% or more with dynamic braking

(optional)

Electronic thermal overload relay; field-programmable

200% of rated current

Ground fault and blown-fuse protection

400/800/1000VDC

190/380/546VDC

Thermostat trips at 90° C

Separate functions for FORWARD, REVERSE, REGEN.; all selectable from 0–300%)

Separate functions for accel, decel, at-speed, and constant horsepower region

Speed deviation, overspeed, mechanical brake failure, lost output phase, failed-oscillator, PGdisconnect, mechanical overload, and roll-back detection

Charge LED is on until DC bus voltage drops below 50VDC

Indoors; requires protection from moisture, corrosive gases, and liquids

14° to 104° F (-10° to 40° C) for NEMA 1; 14° to 122° F (-10° to 50° C) for open chassis

-4° to 140° F (-20° to 60° C)

90% relative; noncondensing

1 G less than 20 Hz; 0.2 G for 20–50 Hz

3300 Ft. (1000M) or less


1-7

DBU & CDBR Units

The DBU (Dynamic Braking Unit) and CDBR are designed to pass regenerative energy from an inverter’s DC bus to a resistor bank. The DBU/CDBR operate when the voltage on the DC bus reaches a specific level which turns on an internal transistor. This transistor stays on until the DC bus voltage drops to an appropriate level. The difference between the turn on and the turn off voltage is the hysteresis voltage.

The DBU/CDBR, and its associated dynamic braking resistor, are used to help the inverter decelerate

AC motors (dynamic braking) and to provide a path for motor regenerative energy under over hauling conditions, such as on a hoist.

DBU Specifications

Characteristic

Required control circuit power supply

Braking start voltage

(1)

Master/Slave mode

Master output

Slave input

Ampacity selection

Fault relay type

Fault relay activation

Resistor temperature switch input

Maximum hysteresis level

Power charge indication

Overcurrent LED

Brake LED

Location

Ambient temperature

Specification

110V; 10VAC; single-phase; 50 to 60 Hz at .2 A; factoryconfigurable for 220VAC 50 to 60 Hz

Jumper-selectable; 330V, 344V, 364V, or 380V for 200V jumper selection; or 629V, 660V, 687V, 727V, or 760V for

400V jumper selection.

Jumper-configurable

Yaskawa CDBR–compatible

Yaskawa CDBR–compatible

Jumper-configurable for IGBTs up to 300 A at 760V

1.

Normally-open

2.

Normally-closed

Relay activates when there is:

• Input control power failure (TB 1-2)

• Internal or external over temperature contact closure

• IGBT overcurrent

Contact closure for over temperature of resistor(s)

Jumper-selectable 1% or 2% of turn on voltage

Charge lamp stays on until bus voltage drops below 70VDC

Activates when overcurrent fault occurs. 5% to 15% above maximum rated current for 5 to 10 minutes; 10 times rated current for 0.1 seconds. Maximum rated currents are:

DBU-24045 75A

DBU-24090

DBU-24160

DBU-24220

150A

200A

300A

Stays on as long as IGBT gate drive is present

Indoors; requires protection from moisture, corrosive gases and liquids

-4°F to 122°F (-20°C to 50°C)


1-8

Specifications (cont.)

Characteristic Specification

Storage temperature

Humidity

Vibration

-4°F to 140°F (-20°C to 60°C)

90% relative (noncondensing)

1G less than 20 Hz; up to 0.2 G at 20–50 Hz

Protective configuration Wall-mounted standard enclosure, including cover, is intended for NEMA 1-rated environments. For NEMA 12,

3R, 4 or other environments, the DBU must be mounted in another enclosure.

(1)

Voltage at which dynamic braking is activated; ±% variance.

External DBU Dimensions

d-4 places

H H1

W1

W

D

Figure 1.1 IMPULSE•VG+ Series 2 Dynamic Braking Unit

Model No.

DBU-24045

DBU-24090

DBU-24160

DBU-24220

Dimensions

in inches (mm)

Mounting Dimensions

in inches (mm)

W H D W1 H1 d

Wt Lb

(kg)

5.69 (144) 11.02 (280) 6.59 (167) 3.94 (100) 10.23 (260) .236 (M6) 7.7 (3.5)

9.64 (245) 14.75 (375) 7.56 (192) 8.26 (210) 13.98 (355) .236 (M6) 27.6 (12.5)

9.64 (245) 14.75 (375) 7.56 (192) 8.26 (210) 13.98 (355) .236 (M6) 27.6 (12.5)

9.64 (245) 14.75 (375) 7.56 (192) 8.26 (210) 13.98 (355) .236 (M6) 27.6 (12.5)


1-9

Minimum Resistor Ohmic Values

The following chart should be used to determine minimum ohmic values for dynamic braking resistors for different supply voltages.

Supply Voltage Turn On Voltage

200V

208V

220V

230V

380V

400V

415V

440V

460V

330V

344V

364V

380V

629V

660V

687V

727V

760V

Minimum Ohmic Value for Braking Resistor

DBU-24045

5.2

5.4

5.7

6.0

9.9

10.4

10.8

11.4

12.0

DBU-24090

4.9

5.2

5.4

5.7

6.0

2.6

2.7

2.9

3.0

DBU-24160

3.7

3.9

4.1

4.3

4.5

1.9

2.0

2.1

2.2

DBU-24220

2.5

2.6

2.7

2.9

3.0

1.3

1.4

1.4

1.5

IMPULSE•VG+ Series 2 External Dynamic Braking Unit—Specifications & Dimensions

External Dynamic Braking Unit Specifications

Specification Information by Model (DBU-XXXX)

24045 24090 24160 24220

Required control circuit power supply

Braking start voltage

Maximum hysteresis error

Power charge indication

Location

(1)

110V; 10VAC

Jumper-selectable; 330V, 344V, 364V, or 380V for 200V jumper selection; or 629V, 660V, 687V, 727V, or 760V for

400V jumper selection.

Jumper-selectable 1% or 2%

Charge lamp stays on until bus voltage drops below 70VDC

Indoors; requires protection from moisture, corrosive gases and liquids

Ambient temperature

Storage temperature

Humidity

Vibration

-4° F to 122° F (-20° C to 50° C)

-4° F to 140° F (-20° C to 60° C)

90% relative (noncondensing)

1G less than 20 Hz; up to 0.2 G at 20–50 Hz

Protective configuration Wall-mounted, enclosed

(1)

Voltage at which dynamic braking is activated; ±2% variance.

NOTE: If a Series 2 drive is used to replace an older version IMPULSE drive, it is permissable to use the older version dynamic braking units (CDBRs).


1-10

CDBR Braking Unit Specification

Braking Unit Model

CDBR

Applicable Motor Output

HP (kW)

Output

Characteristics

Max. Discharge

Current (A

(peak value)*

Rated

Discharge

Current (A)

Braking Start

Voltage

40

15

2015B

20

(15)

Max. Hystersis

Error

VDC

2022B

30

(22)

60

20

200V to 300V

2045

60

(45)

100

30

330/345/365/380V ±3V

Approx. 8V

2110

150

(110)

250

80

243 (1.35 x 200 x 0.9) to 400V peak

Power

Supply

VAC†

Protective

Functions

Environmental

Conditions

Fin Overheat

Power Charge

Indication

Location

Ambient

Temperature

Storage

Temperature

Humidity

Vibration

Protective Configuration

Heat Loss (W) 32

—

38

4030B

40

(30)

40

15

380V to 460V

4045B 4090

60

(45)

120

(90)

60

18

100

30

Indoor (protected from corrosive gases and dust)

+14° to 104°F (-10° to +40°C) (not frozen)

62

90%RH (non-condensing)

1G at less than 20Hz, up to 0.2G at 20 to 50 Hz

Wall-mounted enclosed type

129 54 59 94

4220

300

(220)

250

80

630/660/690/730/760V ±6V

Approx. 16V

460 (1.35 x 380 x 0.9) to 800V peak

Single phase 200 to 220V

50Hz

200 to

230V

60Hz

—

Thermostat

Charge lamp stays ON until bus voltage drops below 50V.

Single phase 380 to460V

50Hz/

60Hz

607 (1.35 x

500 x0.9) to

100V

—

-4° to +140°F (-20° to +60°C)

135

500V to 575V

5037

57

(37)

40

15

825V/950V ±

8V

Approx. 20V

70

* Loading time rate can be used below 10% ED (max. 10 min.)

† AC power supply for cooling fan is used only for models CDBR-2110 and CDBR-4220.


1-11

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:

• Install an input reactor if the power source is greater than 500kVA.

• Install an input reactor if the distance between the drive and the motor exceeds 150 feet.

• 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.

• Install one output reactor per drive for a multiple-drive arrangement requiring reactor protection.

• For a multiple drive arrangement, an input for each drive is recommended for optional 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 an amperage equal to or greater than the sum of the amperage for all the drives.

230V Class

Model Number

2006-FVG+

2008-FVG+

2011-FVG+

2017-FVG+

2025-FVG-

2033-FVG+

2054-FVG+

2068-FVG+

2080-FVG+

2130-FVG+

2160-FVG+

2224-FVG+

2300-FVG+

230V Part Number

REA230-2

REA230-2

REA230-3

REA230-5

REA230-7.5

REA230-10

REA230-20

REA230-25

REA230-30

REA230-50

REA230-60

REA230-75

REA230-100

Maximum Amps of Reactor

25

35

55

80

8

8

12

18

80

130

160

250

300


1-13

460V Class

Model Number

4001-FVG+

4003-FVG+

4005-FVG+

4008-FVG+

4011-FVG+

4014-FVG+

4021-FVG+

4028-FVG+

4034-FVG+

4041-FVG+

4052-FVG+

4065-FVG+

4080-FVG+

4096-FVG+

4128-FVG+

4165-FVG+

4224-FVG+

4302-FVG+

4450-FVG+

4605-FVG+

4605-FVG+

575V Class

5003-FVG+

5004-FVG+

5006-FVG+

5009-FVG+

5012-FVG+

5017-FVG+

5022-FVG+

5032-FVG+

5041-FVG+

5052-FVG+

5062-FVG+

5077-FVG+

5099-FVG+

5130-FVG+

5172-FVG+

5200-FVG+

REA575-2 & 3

REA575-2 & 3

REA575-5

REA575-10

REA575-10

REA575-15

REA575-20 & 25

REA575-30

REA575-40

REA575-50

REA575-60 & 75

REA575-60 & 75

REA575-100

REA575-150

REA575-200

REA575-200

460V Part Number

REA460-1

REA460-2

REA460-5

REA460-5

REA460-7.5

REA460-10

REA460-15

REA460-20

REA460-25

REA460-30

REA460-40

REA460-50

REA460-60

REA460-100

REA460-100

REA460-150

REA460-200

REA460-250

REA460-300

REA460-400

REA460-500

80

100

160

200

200

35

45

55

80

12

12

18

25

4

4

8

Maximum Amps of Reactor

80

110

130

200

35

45

55

80

250

360

480

600

600

12

16

25

35

6

8

2

3


1-14

Interface Cards Specifications

IMPULSE•VG+ Series 2 is designed to interface directly with 120VAC user input and output devices via G5IF, G5IN4, and G5OUT. This eliminates the need for an additional interface relay or isolation circuitry

G5IF has eight optically isolated drive terminals which can be used to connect with the user input device. The Terminal 1 and 2 are always used for the directional run commands (Forward and

Reverse, Up and Down). The rest of six terminals are multi-function terminals, and are used for speed control and other characteristics. With multi-function terminals you can assign various functions and performance characteristics without having to rewire the drive.

G5OUT has two 240VAC, 1.5 Amp solid state relays for output indication devices. It includes two programmable multi-function output terminals.

G5IN4 card has four additional input terminals, which can have a total of 14 sets of input selections.

The individual terminals can be enabled/disabled within a set. For program information refer to

Chapter 5, Programming Advanced Features.

Interface Card Specification

Model Number

G5IF

G5OUT

G5IN4

Rated Input Voltage (AC)

120V

240V

120V

Rated Maximum Current

1.5 Amp

1.5 Amp

1.5 Amp


1-15


c h a p t e r

2

Installation


WA R N I N G

• When preparing to mount the IMPULSE•VG+ Series 2 drive, lift it by its base. Never lift it by the front cover

• Mount the drive on nonflammable material.

• The IMPULSE•VG+ Series 2 drive generates heat. For the most effective cooling possible, mount it vertically. For more details, refer to the “IMPULSE•VG+ Series 2

Dimensions/Heat Loss—Open Chassis” pages 2-9 through 2-12.

• When mounting units in an enclosure, install a fan or other cooling device to keep the intake air temperature below 104

°

F (40

°

C).

Failure to observe these Warnings may result in equipment damage.

This chapter explains the following:

1. Choosing a location

2. IMPULSE•VG+ Series 2 components and external devices

3. Drive environment

4. Drive installation

In addition, this section will cover information on the components that interconnect with

IMPULSE•VG+ Series 2.

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:

NEMA1: +14 to 104

°

F (-10 to 40

°

C).

Open Chassis: +14 to 113

°

F (-10 to 45

°

C)

• 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.)

IMPULSE•VG+ Series 2 Instruction Manual– 5/24/99 Software #14909

2-3

IMPULSE•VG+ Series 2 System Components And External Devices

Standard IMPULSE•VG+ Series 2 Drive Components

• G5IF 120V Control Voltage Interface Card

• G5OUT Control Output Card

Optional Drive Components

• G5IN4 Control Input Card

• D0-08 Control Output Board

• D0-02 Control Output Relay Board

• AI-14B Analog Input Card

As-Required Drive Components

• AC reactor—line or load

• DC bus reactor

• External dynamic braking resistor(s) (See “External Dynamic Braking Unit (DBU)” in Chapter

3, page 3-18.)

• 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, page 3-6.)

• R-C surge suppressors on contactor coils


2-4

Figure 2-1: IMPULSE•VG+ Series 2 Components Diagram Installing the Drive


2-5

Long Time Storage

When an inverter stored for a long time (six months or more) is applied, aging of the main circuit electrolytic capacitor is required.

Execute the aging as follows:

• Main Circuit Electrolytic Capacitor Aging

Voltage applied to the main circuit electrolytic capacitor is slowly added, and it is applied for

60 seconds.

DC Power Supply

Current-limiting Resistance

Several 10th

W

Applied Voltage V

P

L1

L2

L3

N

Inverter Unit

+

V

V

IN

Applied Voltage

V

IN

: 200 V class inverter 360VDC

400 V class inverter 720VDC

0

3 min or greater

6 min or greater t

Caution: For aging, voltage input must NOT be executed from the main circuit terminal L1, L2 and

L3.

Figure 2-2: Long Time Storage


2-6

Installing the Drive

To install IMPULSE•VG+ Series 2

:

1. Ensure the drive will be used in a proper environment. Refer to page 1-4.

2. Review “IMPULSE•VG+ Series 2 Components Diagram” on page 2-5 and “IMPULSE•VG+

Series 2 Terminal Diagram” on page 3-5.

3. Determine the sizes and connection locations for the drive components and external devices that need to be wired. Locate the ground. For exact dimensions, see pages 2-9 through 2-12.

4. Determine the position of the subpanel.

5. Ensure that the drive is positioned vertically so that the heat can dissipate properly.

6. Ensure that the air can flow freely around the heat sink as shown below in Figure 2-3.

Figure 2-3

NOTE:

• The required clearances at the top, bottom, and both sides of the inverter are the same for both open chassis and NEMA 1 enclosures.

•

Allowable intake air temperature: 14

°

F to 104

°

F (-10

°

C to +40

°

C)

• If necessary, a heater or air conditioner must be used to maintain the temperature range listed above.


2-7

7. Lay out the wire runs. Size the wire according to NEC Table 610-14(a). At a minimum, use #16

AWG for control wiring and #12 AWG for power wiring. When performing this step:

• Ensure that the drive control circuit and power circuit wires are perpendicular to each other at any point they cross.

• Keep power and control festoon wiring in separate cables.

• Separate control drive circuit and power circuit wiring on the terminal block strip.

8. Obtain the appropriate hardware for mounting.

9. Mount the subpanel or surface to which you are mounting the drive. (Contact Electromotive

Systems if you need advice on mounting, especially for larger drives.)

10. Fasten the drive and components to the subpanel.

11. Remove the keypad from the front cover by pushing the depression area and lifting the keypad as shown below in Figure 2-4.

Figure 2-4

12. Remove the drive cover. For Models 2003-FVG+ through 2033-FVG+ and 4001-FVG+ through

4014-FVG+. See Figure 2-5. On larger size drives, the cover is attached with screws.

Figure 2-5

13. Remove the G5OUT Card (if used).

14. Remove the G5IF Card.

15. Follow the wiring practices outlined in Chapter 3.


2-8

IMPULSE•VG+ Series 2 Dimensions/Heat Loss—Open Chassis

d-4 places

Air

Flow

H

H1 fddf fddf fddf fddf fddf ivnch diei inch enter data

Go inch shift

Stop inch enter data

Model

2006-FVG+

2008-FVG+

2011-FVG+

2017-FVG+

2025-FVG+

2033-FVG+

2054-FVG+

2068-FVG+

2080-FVG+

2130-FVG+

2160-FVG+

2224-FVG+

2300-FVG+

W1

W

D

Figure 2-6: 230V—Open Chassis

NOTE: Some models are shipped with metal enclosures that can be removed and discarded.

Overall Dimensions in inches and (mm)

W

7.87

(200)

7.87

(200)

9.84

(250)

9.84

(250)

5.51

(140)

5.51

(140)

5.51

(140)

5.51

(140)

12.80

(325)

16.73

(425)

16.73

(425)

18.70

(475)

22.64

(575)

H

11.81

(300)

11.81

(300)

14.96

(380)

14.96

(380)

11.02

(280)

11.02

(280)

11.02

(280)

11.02

(280)

17.72

(450)

26.57

(675)

26.57

(675)

31.50

(800)

36.42

(925)

D

8.07

(205)

8.07

(205)

8.86

(225)

8.86

(225)

6.30

(160)

6.30

(160)

7.09

(180)

7.09

(180)

11.22

(285)

13.78

(350)

13.78

(350)

13.78

(350)

15.75

(400)

Mounting Dimensions in inches and (mm)

W1

7.32

(186)

7.32

(186)

9.29

(236)

9.29

(236)

4.95

(126)

4.95

(126)

4.95

(126)

4.95

(126)

10.83

(275)

12.60

(320)

12.60

(320)

14.57

(370)

17.52

(445)

H1

11.22

(285)

11.22

(285)

14.37

(365)

14.37

(365)

10.47

(266)

10.47

(266)

10.47

(266)

10.47

(266)

17.13

(435)

25.59

(650)

25.59

(650)

30.51

(775)

35.24

(895)

H2

0.31

(8)

0.31

(8)

0.30

(7.62)

0.30

(7.62)

0.28

(7)

0.28

(7)

0.28

(7)

0.28

(7)

0.30

(7.62)

0.49

(12.5)

0.49

(12.5)

0.49

(12.5)

0.59

(15)

Wt Lbs/(kg)

12

(5.5)

13

(6)

24

(10.8)

24

(10.8)

6.5

(3)

6.5

(3)

10

(4.5)

10

(4.5)

62

(28)

134

(61)

137

(62)

176

(80)

298

(135)

Heat Loss

(W)

Total

90

120

140

215

300

345

585

725

885

1370

1730

2630

3210


2-9


d-4 places

Air

Flow

H


Go inch shift


W1

W

D

Figure 2-7: 460V Class—Open Chassis


Model

4001-FVG+

4041-FVG+

4052-FVG+

4065-FVG+

4080-FVG+

4096-FVG+

4128-FVG+

4165-FVG+

4224-FVG+

4003-FVG+

4005-FVG+

4008-FVG+

4011-FVG+

4014-FVG+

4021-FVG+

4028-FVG+

4034-FVG+

Overall Dimensions—in. &

(mm)

W

12.80

(325)

12.80

(325)

17.91

(455)

17.91

(455)

22.64

(575)

9.84

(250)

12.80

(325)

12.80

(325)

12.80

(325)

5.51

(140)

7.87

(200)

7.87

(200)

9.84

(250)

5.51

(140)

5.51

(140)

5.51

(140)

5.51

(140)

H

24.61

(625)

24.61

(625)

32.28

(820)

32.28

(820)

36.42

(925)

14.96

(380)

17.72

(450)

17.72

(450)

24.61

(625)

11.02

(280)

11.81

(300)

11.81

(300)

14.96

(380)

11.02

(280)

11.02

(280)

11.02

(280)

11.02

(280)

D

11.22

(285)

11.22

(285)

13.78

(350)

13.78

(350)

14.76

(375)

8.86

(225)

11.22

(285)

11.22

(285)

11.22

(285)

7.09

(180)

8.07

(205)

8.07

(205)

8.86

(225)

6.30

(160)

6.30

(160)

7.09

(180)

7.09

(180)

Mounting Dimensions—in. &

(mm)

W1

10.83

(275)

10.83

(275)

13.78

(350)

13.78

(350

17.52

(445)

9.29

(236)

10.83

(275)

10.83

(275)

10.83

(275)

4.95

(126)

7.32

(186)

7.32

(186)

9.29

(236)

4.95

(126)

4.95

(126)

4.95

(126)

4.95

(126)

H1

24.02

(610)

24.02

(610)

31.30

(795)

31.30

(795)

35.24

(895)

14.37

(365)

17.13

(435)

17.13

(435)

24.02

(610)

10.47

(266)

11.22

(285)

11.22

(285)

14.37

(365)

10.47

(266)

10.47

(266)

10.47

(266)

10.47

(266)

H2

0.30

(7.5)

0.30

(7.5)

0.49

(12.5)

0.49

(12.5)

0.59

(15)

0.30

(7.5)

0.30

(7.5)

0.30

(7.5)

0.30

(7.5)

0.28

(7)

0.31

(8)

0.31

(8)

0.30

(7.5)

0.28

(7)

0.28

(7)

0.28

(7)

0.28

(7)

Wt Lbs/(kg)

97

(44)

97

(44)

174

(79)

176

(80)

298

(135)

24

(11)

60

(27)

60

(27)

97

(44)

10

(4.5)

13

(6)

13

(6)

24

(11)

6.5

(3)

6.5

(3)

8.8

(4)

10

(4.5)

Heat Loss

(W)

Total

60

85

110

145

200

220

360

455

570

660

880

1020

1245

1385

1820

2320

3030


2-10

Model

4302-FVG+

4450-FVG+

4605-FVG+


(mm)

W

22.64

(575)

37.40

(950)

37.80

(960)

H

36.42

(925)

57.09

(1450)

62.99

(1600)

D

15.75

(400)

17.13

(435)

17.91

(455)


(mm)

W1

17.52

(445)

29.53

(750)

29.53

(750)

H1

35.24

(895)

55.12

(1400)

61.02

(1550)

H2

0.59

(15)

0.98

(25)

0.98

(25)

Wt Lbs/(kg)

320

(145)

794

(360)

926

(420)

Heat Loss

(W)

Total

4190

6850

9730


2-11


d-4 places

Air

Flow

H


Go inch shift


W1

W

D

Figure 2-8: 575V Class—Open Chassis


Model

5003-FVG+

5041-FVG+

5052-FVG+

5062-FVG+

5077-FVG+

5099-FVG+

5130-FVG+

5172-FVG+

5200-FVG+

5004-FVG+

5006-FVG+

5009-FVG+

5012-FVG+

5017-FVG+

5022-FVG+

5027-FVG+

5032-FVG+


(mm)

W

22.64

(575)

22.64

(575)

22.80

(579)

22.80

(579)

22.80

(579)

15.75

(400)

22.64

(575)

22.64

(575)

22.64

(575)

7.87

(200)

9.84

(250)

9.84

(250)

15.75

(400)

5.51

(140)

5.51

(140)

7.87

(200)

7.87

(200)

H

29.53

(750)

33.46

(850)

33.46

(850)

33.46

(850)

41.34

(1050)

41.97

(1066)

57.68

(1465)

77.43

(1966.5)

77.43

(1966.5)

11.81

(300)

14.96

(380)

14.96

(380)

29.53

(750)

11.02

(280)

11.02

(280)

11.81

(300)

11.81

(300)

D

12.80

(325)

12.80

(325)

12.99

(330)

13.98

(355)

13.98

(355)

11.22

(285)

11.81

(300)

11.81

(300)

11.81

(300)

8.07

(205)

8.86

(225)

8.86

(225)

11.22

(285)

7.09

(180)

7.09

(180)

8.07

(205)

8.07

(205)


(mm)

W1

18.70

(475)

18.70

(475)

18.70

(475)

18.70

(475)

18.70

(475)

11.81

(300)

18.71

(475)

18.71

(475)

18.71

(475)

7.32

(186)

9.29

(236)

9.29

(236)

11.81

(300)

4.96

(126)

4.96

(126)

7.32

(186)

7.32

(186)

H1

40.35

(1025)

40.35

(1025)

48.23

(1225)

61.81

(1570)

61.81

(1570)

28.74

(730)

32.48

(825)

32.48

(825)

32.48

(825)

11.22

(285)

14.37

(365)

14.37

(365)

28.74

(730)

10.47

(266)

10.47

(266)

11.22

(285)

11.22

(285)

H2

0.49

(12.5)

0.49

(12.5)

0.49

(12.5)

0.59

(15)

0.59

(15)

0.39

(10)

0.49

(12.5)

0.49

(12.5)

0.49

(12.5)

0.31

(8)

0.29

(7.5)

0.29

(7.5)

0.39

(10)

0.28

(7)

0.28

(7)

0.31

(8)

0.31

(8)

Wt Lbs/(kg)

195

(90)

195

(90)

271

(125)

331

(153)

342

(158)

97

(44)

156

(72)

156

(72)

156

(72)

14

(6.5)

28

(13)

28

(13)

97

(44)

8.8

(4)

8.8

(4)

13

(6)

14

(6.5)

Heat Loss

(W)

Total

90

105

140

205

220

330

460

540

730

820

1220

1650

1750

2250

2350

3200

4700


2-12

c h a p t e r

3

Wiring


IMPULSE•VG+ Series 2 Wiring Practices

W A R N I N G

Before you wire the drive, review the following practices to help ensure that your system is wired properly.

• Do not connect the main output terminals (T1, T2, and T3) to the incoming, three-phase AC source. This will damage the unit!

• Except for Terminals 18, 19, and 20, do not connect the control board terminals directly to the

120VAC user input device. This will damage the unit!

• Ensure that the drive-to-motor wiring distance is less than 250 ft unless appropriate reactors and/ or filters are used.

• If a device that can interrupt power is installed between the drive and the motor, install a reactor on the output side of the drive.

• On external user input devices, use hard contact inputs rather than solid-state inputs.

• If the power source is 500 kVA or greater, or more than 10 times the inverter kVA rating, ensure that there is at least 3 percent impedance between the power source and the drive input. To accomplish this, you can install a DC reactor between inverter terminals

⊕

1 and

⊕

2, or use an

AC line reactor on the input of the drive. If you don’t provide enough impedance, excessive peak currents could damage the input power supply circuit.

• If the user input device is a PLC TRIAC output, use a 5-K

Ω

, 10-W resistor between the signal and L2 (X2).

• Comply with “Suggested Circuit Protection Specifications” on page 3-6.

• Use time delay fuses, which are sized at 150% of drive's continuous-rated current, for drive input protection.

• Use R-C–type surge absorbers across the coil of all contactors and relays in the system. Failure to do so could result in noise-related, nuisance fault incidents. For selection information, see

“R-C Surge Absorber Selection” on page 3-33.

• Use external dynamic braking resistors for all applications.

• Do not ground the drive with any large-current machines.

• Before you use any welding or high-current machines near the crane, disconnect all line and ground wiring.

• Do not use output contactors between the drive and the motor.

• Do not let the wiring leads come in contact with the drive enclosure.

• Do not connect power factor correction capacitors to the drive input or output.

• Hard-wire the drive and motor (e.g., festoon cable). Do not use sliding collector bars.

• If you have a user input device or interface board that is remote, use shielded cable between the drive input terminals and the interface output terminals or user input device(s).

• Before turning on the drive, check the output circuit (T1, T2 and T3) for possible short circuits and ground faults.


3-3

• Increase the wire size by one size for every 25 ft between the drive and motor; suggested for center driven cranes, trolleys and bridges. (Voltage drop is especially significant at low frequencies.)

• When using more than one transformer for the drive's power, properly phase each transformer.

• To reverse the direction of rotation, interchange any two motor leads (T1, T2 or T3). (Changing

L1, L2 or L3 will not affect the shaft rotation direction.)

• Use shielded cable for all low-level DC speed reference signals (0 to10VDC, 4 to 20 mA).

Ground the shield only at the drive side.

• Please observe National Electrical Code (NEC) guidelines when wiring electrical devices.

Failure to observe these warnings may result in equipment damage.


3-4

IMPULSE•VG+ Series 2 Standard Connection Diagram

Figure 3-1: IMPULSE•VG+ Series 2 Terminal Diagram

NOTE: Wiring may vary between DBU and CDBR.


3-5

Suggested Circuit Protection Specifications and Wire Size

In order to comply with most safety standards, some circuit protective devices should be used between the incoming three-phase power supply and the IMPULSE•VG+ Series 2. These devices can be thermal, magnetic, or molded-case breakers (MCCB); or “slow-blow” type fuses such as

“CCMR” or “J.”

C A U T I O N :

The following guidelines are only suggested values. Always conform to local electrical codes and wiring practices.

Rated Current(A) Time Delay

Input Fuse

Class

Inverse Time

Wiring Size (AWG/MCM)

Molded/Case

Circuit Breaker

Power Circuit

Wiring

Control

Wiring Model #

230VClass

2006 -FVG+

2008 -FVG+

2011 -FVG+

2017 -FVG+

2025 -FVG+

2033 -FVG+

2054 -FVG+

2068 -FVG+

2080 -FVG+

2130 -FVG+

2160 -FVG+

2224 -FVG+

2300 -FVG+

460VClass

4001 -FVG+

4003 -FVG+

4005 -FVG+

4008 -FVG+

4011 -FVG+

4014 -FVG+

4021-FVG+

4028 -FVG+

4034 -FVG+

4041 -FVG+

4052-FVG+

4065 -FVG+

4080 -FVG+

4096 -FVG+

Drive

54

68

80

130

160

224

300

6

8

11

17.5

25

33

InputFuse

70

90

100

175

200

300

400

25

35

45

9

12

20

J

J

J

J

J

J

J

J

J

J

CC

CC

CC

100

100

175

250

300

450

600

40

60

70

15

20

25

34

41

52

65

80

96

1.9

3.6

5.1

8.5

11.7

14.8

21

28.6

45

60

70

90

100

125

20

25

30

40

3

6

8

15

J

J

J

J

J

J

J

J

CC

CC

CC

CC

CC

CC

80

80

125

125

150

200

25

30

50

60

10

10

15

20


3-6

12

10

10

12

12

12

6

4

4

1/0

1/0

4/0

2/0 x 2P

6

6

8

8

4

2

12

12

10

10

12

12

12

12

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

Ground

4

2

1

8

6

6

4

14/10

12/10

12/10

10

10/8

10/8

8

8

8

8

6

6

12/10

12/10

12/10

12/10

8

8

12/10

8/6

Model #

4128 -FVG+

4165 -FVG+

4224 -FVG+

4302 -FVG+

4450 -FVG+

4605 -FVG+

575V Class

5003-FVG+

5004-FVG+

5006-FVG+

5009-FVG+

5012-FVG+

5017-FVG+

5022-FVG+

5027-FVG+

5032-FVG+

5041-FVG+

5052-FVG+

5062-FVG+

5077-FVG+

5099-FVG+

5130-FVG+

5172-FVG+

5200-FVG+

77

99

130

172

200

32

41

52

62

3.5

4.1

6.3

9.8

12.5

17

22

27

Drive

128

165

224

302

450

605

Rated Current(A)

InputFuse

175

225

300

400

600

800

Time Delay

J

J

J

J

J

L

Input Fuse

Class

Inverse Time


Molded/Case

Circuit Breaker

250

350

450

600

900

1450

Power Circuit

Wiring

1/0

2/0

4/0

2/0 x 2P

2/0 x 2P

250 MCM x 2P

Control

Wiring

16/14

16/14

16/14

16/14

16/14

16/14

100

125

175

225

300

45

60

70

90

20

25

35

40

5

7

10

15

J

J

J

J

J

J

J

J

J

J

J

CC

CC

CC

CC

CC

CC

150

200

250

350

450

80

80

125

125

30

40

50

60

10

10

15

20

4

2

1/0

2/0

4/0

6

4

10

8

12

12

10

10

12

12

12

12

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

4

4

6

6

2

8

8

8

8

12/10

12/10

12/10

12/10

8

8

12/10

8/6

Ground

2

1

4

4

1/0

1/0

.


3-7

Power Circuit Wiring Procedures

To wire the power circuit for IMPULSE•VG+ Series 2:

1. Run the three-phase power supply wires through an appropriate enclosure hole.

2. Referring to “Suggested Circuit Protection Specifications—IMPULSE•VG+ Series 2” and the following two tables, connect the three-phase power supply wires to a circuit protection system.

3. Connect the three-phase power supply wires from the circuit protection Terminals L1, L2 and

L3.

4. From Terminals T1, T2 and T3, connect the power output wires to the motor. If a load reactor is used, connect these output wires to the reactor input instead; then connect the reactor output to the motor.

NOTE: If a device that can interrupt power is installed between the drive and the motor, install a reactor on the output side of the drive.

5. For Models 4041-FVG+ and greater, ensure the jumper plug is inserted in the printed-circuit board (3PCB), which is underneath the control board, as follows:

Figure 3-2: Models 4041-FVG+ to 4096-FVG+

Figure 3-3: Models 4128-FVG+ to 4605-FVG+


3-8

Installation/Wiring of CDBR Braking Unit

The following wiring instructions apply to Figures 3-4 (page 3-10) through 3-8 (page 3-14).

W A R N I N G

120 VAC is not needed for the control circuit to operate. If 120 VAC is applied to terminals 1, 2, 5 or 6, DAMAGE TO THE UNIT WILL RESULT.

NOTE: • Some Braking units have only a symbol labeling the terminal.

• Most resistors do not have P

0

(

r

0

) and B (

s

0

) designators.

• Polarity does not matter on the resistor.

1. Wire N ( s

) on the CDBR to N ( s

) on the drive.

2. Wire P ( r

) on the CDBR to P( r

) on the drive.

3. Wire the P

0

( r

0

) on the CDBR to the dynamic braking resistor.

4. Wire B ( s

0

) on the CDBR to the dynamic braking resistor.

5. For CDBR Model #4220, wire

r

on the CDBR to

r

(

l

1) on the drive. For Drive Model numbers

4096-AFG+ and 4096-FVG+ and below, wire

s on the CDBR to

s

(

l

2) on the drive. For Model numbers 4128-AFG+ and 4128-FVG+ and above, wire

s

on the CDBR to

s

400 (

l

2 400) on the drive.

6. Terminals 3 and 4 are the Cooling Fin Overheat Contact.

Thermoswitch contact rating: 250VAC, 1A max

30VDC, 1A max

7. Terminals 1, 2 , 5 and 6 are used for MASTER/SLAVE Operation. Use twisted-pair wires of 14

AWG or smaller for connection between 5, 6, and 1, 2 on the braking units. Parallel connection is possible up to a maximum of 10 units. Refer to Figure 3-5 on page 3-11 for parallel connection of braking units.

8. Set the Voltage Selection Jumper to match the voltage of the incoming power source.

9. Set the Master/Slave Jumper to Master for single unit operation.


3-9

Figure 3-4: CDBR 4045B


3-10

Figure 3-5: CDBR Parallel connection of Braking Unit


3-11

Figure 3-7: CDBR 4090


3-13

Figure 3-8: CDBR 4220


3-14

230 V Class Terminal Functions

Model

2006-FVG+ to 2033-FVG+

6 to 33 Amps

2054-FVG+ to 2068-FVG+

54 to 68 Amps

Rated Current

L1

L2

L3

T1

T2

T3

B1

B2 s

⊕

1

⊕

2

⊕

3 r s

Braking resistor

DC reactor (

⊕

1–

⊕

2)

DC Power supply (

⊕

1– s

) n/a

2080-FVG+

80 Amps

Main circuit input power supply

Inverter output

DC reactor (

⊕

1–

⊕

2)

DC power supply (

⊕

1–

⊕

)

Braking unit (

⊕

3– s

) n/a

2130-FVG+ to 2300-FVG+

130 to 300 Amps

DC power supply (

⊕

1– s

)

Braking unit (

⊕

3– s

)

(

⊕

1 and

⊕

2 terminals not provided)

Cooling fan power supply

Ground terminal (Ground resistance: 100

Ω

or less)

460 V Class Terminal Functions

Model

4003-FVG+ to 4034-FVG+

3.6 to 34 Amps

4041-FVG+ to 4096-FVG+

41 to 96 Amps

Rated Current

L1

L2

L3

T1

T2

T3

B1

B2 s

⊕

1

⊕

2

⊕

3 s r s200 s400

Braking resistor

DC reactor (

⊕

1–

⊕

2)

DC power supply (

⊕

– s

) n/a n/a

DC power supply (

⊕

1–

Braking unit (

⊕

3– s

) s

)

Cooling fan power supply n/a

4128-FVG+ to 4302-FVG+

128 to 302 Amps


Inverter output n/a

4450-FVG+ to 4605-FVG+

450 to 605 Amps

Braking unit (

⊕

3– s

)

(

⊕

1 and

⊕

2 terminals not provided) n/a


(Control power supply) r–s200: 200 to 230VAC input r–s400: 380 to 460VAC input


Ω

or less


3-16

575 V Class

Rated Current

L1 (R)

L2 (S)

Model

L3 (T)

T1 (u)

T2 (V)

T3 (W)

B1

B2 s

⊕

1

⊕

2 l 1(r) l 2(s)

5003-FVG+ to 5032-FVG+

3 to 32 Amps

DC reactor (

⊕

1–

⊕

2)

DC power supply (

⊕

–

Braking Unit(

⊕

– s

) s

)

Braking resistor n/a

5003-FVG+ to 5017-FVG+

3 to 17 Amps


Inverter output

5041-FVG+ to 5200-FVG+

41 to 200 Amps

DC power supply (

⊕

1–

Braking unit (

⊕

1– s

) s

)

(

⊕

2 terminal not provided) n/a



Ω

or less)


3-17

External Dynamic Braking Unit (DBU)

For applications that require more than one External DBU, wire the DBUs in parallel as shown in

Figures 3-4 (page 3-10) through 3-8 (page 3-14), 2130-FVG+ to 2300-FVG+, and 4128-FVG+ to

4302-FVG+, and 4450-FVG+ to 4605-FVG+.

You can connect up to 10 of these units in a “master/slave” configuration. An application can have multiple slaves, but only one master. With this configuration, ensure that you connect all of the thermal switches (Terminals 3 and 4) in parallel and connect them to your RUN circuitry. Use twisted-pair, shielded cable (Belden 8760) for this control circuitry. For more information on the

DBU, see “IMPULSE•VG+ Series 2 External Dynamic Braking Unit—Specifications &

Dimensions.”

NOTE: The wiring distance between the DBU and IMPULSE•VG+ Series 2 must be less than 16.4 feet (5 m). The wiring distance between the DB resistor and the DBU must be less than

32.8 feet (10 m).

10. Run the wires into the DBU through the holes in the bottom of its enclosure.

NOTE: The maximum wire size for a single DBU is #6.

11. Make a cross cut in the rubber bushings supplied with the unit.

12. Run the wires through a hole in both the drive and the DBU. (This will provide the DBU components with an extra degree of protection from the environment.)

13. Connect DBU terminals to the drive as indicated in “Detailed Power Circuits—By Model,” found on pages 3-22 through 3-27.

14. “Jumper” JP5, and then JP4, on the DBU logic card, as indicated in the following two drawings, to correspond with the incoming line voltage.

Figure 3-10: 200V


3-18

Figure 3-11: 400V

External Dynamic Braking Resistor

15. Referring to the drawings in “Detailed Power Circuits—By Model” found on pages 3-22 through

3-27, connect the dynamic braking resistor(s) as follows:

• For Models 2003-FVG+ through 2033-FVG+ through 4034-FVG+, connect the resistor(s) to terminals B1 and B2.

• For all other models, connect the resistor(s) to terminals PO and B on the External DBU.


3-19

Grounding

16. Connect terminal G to the common panel ground. Use ground wiring as specified in “Suggested

Circuit Protection and Wire Size” on page 3-38, and keep the length as short as possible.

• Ground Resistance: 230V class; 100

Ω

or less, 460V or greater class; 10

Ω

or less.

• Never ground the IMPULSE•VG+ Series 2 drives in common welding machines, motors, or other high-current electrical equipment. Run all ground wiring in separate conduit.

• When more than one drive is used for the same system, ground each directly or daisy-chain to the ground pole. Do not loop the ground wires.

Figure 3-12: Grounding

.


3-20

Power Circuit Wiring Diagrams

Figure 3-13: Power Circuit Wiring Diagram


3-21

Detailed Power Circuits—By Model

The following ten drawings show detailed power wiring circuits by model.

NOTE: If a Series 2 drive is used to replace an older version IMPULSE drive, it is permissable to use the older version dynamic braking units (CDBRs).

Figure 3-14: 2006-FVG+ to 2008-FVG+

Figure 3-15: 2011-FVG+ to 2033-FVG+

NOTE: Wiring will vary between DBU and CDBR.


3-22

Figure 3-21: 4041-FVG+ to 4096-FVG+

Figure 3-22: 4128-FVG+ to 4302-FVG+



3-26

Figure 3-23: 4450-FVG+ to 4605-FVG+



3-27

Wiring the Control Circuit

Control Input

IMPULSE•VG+ Series 2 is designed to interface directly with a 120VAC user input device. User input devices include: pendant controls (pushbutton station), remote control transmitters (infrared and radio), master switches, programmable logic controls (PLC), and personal computers. This design feature eliminates the need for interface relays or isolation circuitry. The user interface device is connected to the G5IF 120V Control Interface Card, which includes Terminals 1, 2, 3, 4, 5,

6, 7, and 8. Four more terminals can be added with the optional G5IN4 120V Control Input Card.

NOTE: Terminal X2 is also on both control input cards, and should always be connected to X2 of the user input device.

For the G5IF, Terminals 1 and 2 are always used for the directional run commands (FORWARD,

REVERSE, UP, DOWN, LEFT, RIGHT). The other terminals are multi-function terminals, and are used for speed control and other characteristics. With multi-function terminals you can assign entirely different functions and performance characteristics without having to rewire the drive.

Additional Input Terminals

Four additional digital input terminals can be added with the optional G5IN4 120V input card. To program the G5IN4 input card, please refer to Chapter 5; “Special Function Group, G5IN4 Digital

Multi-Function Inputs” Sections (C9-XX) on page 5-40.

Control Output

The table below summarizes the control output terminal functions:

Circuit Board

G5OUT

G5OUT

G5OUT

Drive Control Board

Drive Control Board

Drive Control Board

Drive Control Board

Drive Control Board

Terminal Function

9

10

18

19

20

C

01

02

Connection to X1 of 120VAC power supply

Multi-function Output (See H2 constants)

Multi-function Output (See H2 constants)

Electric brake output; electric brake release signal

Electric brake output; electric brake release signal

Fault output—normally open; closed to COM at fault

Fault output—normally closed; open to COM at fault

Fault output—common


3-28

Control Circuit Terminals

The table below outlines the functions of the control circuit terminals.

Classification Terminal

Sequence

Input Signal

8

11

6

7

4

5

1

2

3

15

Signal Function

Forward run/stop

Reverse run/stop

Speed 2

Speed 3

Speed 4

Speed 5

External Fault

M-Speed Gain 1

Sequence control input common terminal

+15V

Power supply output

Description

Forward run when closed, stop when open

Reverse run when closed, stop when open

Multi-function contact inputs (H1-01 to H1-06)

–

For analog command +15V power supply

Analog

Input Signal

Sequence

Output Signal

Analog

Output Signal

33

13

14

16

17

12

9

10

19

20

21

22

25

26

27

18

23

Signal Level

Photo-coupler isolation

Input: +24VDC 8mA

-15V

Power supply output

Master frequency reference

Multi-function analog reference

For analog command -15V power supply

-10 to +10V/-100% to 100%

0 to +10V/0 to 100%

4 to 20 mA/0 to 100%

-10 to +10V/-100% to 100%

0 to 10 V/0 to 100%

-10 to +10V/-100% to +100%

0 to +10 V/0 to 100%

0V

Multi-function analog reference

(H3-05)

Auxiliary analog input (H3-05)

+15V

(Allowable current 20 mA max.)

-15V

(Allowable current 20 mA max.)

-10 to +10V (20k

Ω

),

0 to +10V/(20k

Ω

)

4 to 20mA (250

Ω

)

-10 to +10V (20k

Ω

),

0 to +10V/(20k

Ω

)

-10 to +10V (20k

Ω

),

0 to +10V/(20k

Ω

)

–

Multi-function analog input

Common terminal for control circuit

Connection to shield sheath of signal lead

– –

Brake output

Multi-function output (H2-01 to H2-03)

Dry contact

Contact capactiy:

250VAC, 1A or less

30VDC, 1A or less

Open collector output

48V, 50mA or less

Brake output

Fault annunciate

Open collector output common

Fault contact output

(NO/NC contact)

Fault when closed between terminals 18 and 20

Fault when open between terminals 19 and 20

Frequency meter output 0 to ± 10V/0 to 100% frequency

Common

Current monitor 5V/inverter rated current

Multi-function analog monitor

(H4-01 to H4-03)

Multi-function analog monitor 2

(H4-04 to H4-06)

–

Dry contact

Contact capacity:

250VAC 1A or less

30VDC 1A or less

0 to ±11V Max. ±5%

2mA or less


3-29

Control Circuit Wiring Procedures

To wire the drive control circuit for IMPULSE•VG+ Series 2:

1. While the G5IF 120V Control Voltage Interface and G5OUT Control Output Cards are already attached to the drive control terminals when the drive is shipped, the figure below in provided in case you have to reattach these boards.

Figure 3-24: Interface Cards


3-30

2. Connect input terminals—X2, 1, 2, 3, 4, 5, 6 and 7 for G5IF and X2, 1, 2, 3 and 4 for G5IN4—to the user input device. The following drawing shows a typical five-speed interconnection and should help you understand how to wire any control circuit application. For more information on multi-function inputs, see

Terminal 3 Sel

(H1-01) through

Terminal 8 Sel

(H1-06) in Chapter 5 on page 5-72, Terminal Parameters Group, Digital Inputs Section.

Figure 3-25: Five-Step Multi-Speed Terminal Diagram (Example)

3. Install G5OUT card to the drive as indicated in Figure 3-24 “Interface Cards” on page 3-30.

4. Connect the output terminals, as indicated in the following drawing, to the intended output device(s).


3-31

Figure 3-25: Output Terminals

5. Connect the G5IF common lead (blue wire W11) to Terminal 11 on the drive control terminal.

Refer to Figure 3-24 “Interface Cards” on page 3-30.

NOTE: If the drive is being applied in a no-load brake hoist application, Electromotive

Systems recommends the use of an external warning device wired to terminal 2 of the

G5OUT card. Reference No-Load Brake Start/Stop and Digital Outputs – Fault

Annunciate in Chapter 5 on page 5-31 for more details.


3-32

R-C Surge Absorber Selection

6. Install R-C-type surge absorbers across the coils of any contactors installed in the drive’s control panel enclosure. Refer to the following table when selecting surge absorbers.

Applied VAC

120 VAC (1Ø)

240VAC (1Ø)

480VAC (3Ø)

Application

Contactor or magnetic brake coils

Contactor or magnetic brake coils

Brake coils

Resistance

100

Ω

150

Ω

220

Ω

100

Ω

150

Ω

220

Ω

100

Ω

220

Ω

R-C Surge Absorber

Part Number

RCS1C6

(3), (4)

RCS1H6

RCS1A6

RCS2G6

RCS2H6

RSC2A6

RCY6G-30

RCY6A-30

(1)

Part numbers are those of R-K Electronics, and are available from Electromotive Systems.

(2)

All surge absorbers .47 microfarads.

(3)

The surge absorber most often used by Electromotive Systems.

(4)

If an A-B–type contactor (IEC–type) is used, then part number used is A-B 199-FSMA1.

(1), (2)

Electric Brake Coil and Reattachment

7. Connect 110VAC supply (X1) to Terminal 9, the electric brake contactor coil to Terminal 10, and the other side of the contactor coil to the 110V return (X2).

8. Reattach the G5IF card to the lower-level control board Terminals 1 through 8. (Refer to Figure

3-24 “Interface Cards” on page 3-30.)

9. Reattach the G5OUT card to top-level control board Terminals 17, 25, 26, 27, and 33. (Refer to

Figure 3-24 “Interface Cards” on page 3-30.)

Cover and Keypad

NOTE: Before you perform the following step, wire the encoder circuit, which is explained in

“Wiring the Encoder Circuit” in the following section.

10. Refasten the cover, inserting the top of the cover first.


3-33

11. Referring to the following drawing, reinsert the keypad in the keypad well of the cover by aligning the keypad with the claws and locking the keypad into place.

Figure 3-27: Cover and Keypad


3-34

Wiring the Encoder Circuit

A shaft-mounted encoder is required to provide speed and shaft position feedback to

IMPULSE•VG+ Series 2. Without an encoder, a flux vector control cannot operate properly.

Before you wire the encoder circuit, refer to the specification tables in this section and to “Wiring

Specifications.”

Encoder Circuit Wiring Procedures

Encoder Specifications

Power supply

Output Type

Type of output circuit

Resolution

Mounting method

+12VDC; if current demand is greater than 200 mA, an auxiliary power supply must provided

Quadrature (A and B channels; Z is not necessary)

High-speed, differential line drive

1024 PPR

Encoder must be direct-coupled to motor shaft, using a zero-backlash-type coupling.

To wire the encoder circuit for IMPULSE•VG+ Series 2 (assuming the cover and keypad are detached):

1. Direct-couple the encoder to the motor shaft, using a zero-backlash-type coupling.

NOTE: Do not connect the encoder to the motor with roller chain or gear drive. If unable to direct-couple the encoder, use a timing belt to drive the encoder. (Contact

Electromotive Systems for encoder kits.) Also, do not connect the encoder to the lowspeed shaft of a speed reducer.

2. Connect the encoder to the PG-X2 Encoder Interface Card. Refer to Figure 3-29: “Generic

Encoder” and Figure 29: “PG-X2 Interface Card Terminal Functions” on page 3-36.

NOTE: Use twisted-pair, shielded cable (Electromotive R-20/6, Belden 9730, or Brand Rex T-

11651). Strip the encoder wires .25 in. (5.5 mm). Keep the wiring length less than

300 feet. (For cable lengths greater than 300 feet, contact Electromotive Systems for information on available fiber optic cable systems.)

3. Ground the shielded cable to Terminal TA-3 of the PG-X2 Encoder Interface Card. (Ground only one end of the shielded cable.)

NOTE: For LakeShore encoders, the shield connection is not considered “Ground.” The shield should be grounded at TA-3 and connected to the shield at the encoder.


3-35

Encoder Wiring Diagrams and Information

Figure 3-28: Generic Encoder

The following drawing and table shows you how to connect a LakeShore Model 8500 encoder to the

PG-X2 Encoder Interface Card.

Figure 3-29: LakeShore Model 8500 Encoder


3-36

Lakeshore Model SL56 Encoder Wiring Scheme

Encoder Signal

+5 to 15VDC

OV

A+

A-

B+

B-

Shield

Wire Color

Red

Black

Blue

Gray

Green

Yellow

N/A

PG-X2 Terminal (TA-1)

6

7

TA3

4

5

1

2

PG-X2 Encoder Interface Card Specifications

Power supply to encoder:

Encoder input signal:

Pulse monitor output signal (repeater):

Pulse phases accepted:

Maximum input frequency:

Connector type:

Dual; +12VDC; 200 mA maximum

RS-422–level, line-driver-type

RS-422–level, line-driver-type

Phases A and B (both + and -)

300 kHz

Phoenix MKDS1 series

PG-X2 Encoder Interface Card Terminal Functions

Terminal

Block

TA1

TA2

TA2

TA2

TA2

TA2

TA3

TA1

TA1

TA1

TA1

TA1

TA1

TA1

Pin #

4

7

–

2

3

10

1

6

7

4

5

1

2

3

Function

+12VDC power supply; do not use Pins 1 and 3 together

Power supply common

Alternate 5VDC power supply for encoder; do not use Pins 1 and 3 together

A+ pulse input

A- pulse input

B+ pulse input

B- pulse input

Ground

A-pulse output

A-pulse output

B-pulse output

B-pulse output

Common signal ground terminal

Shielded-sheath connection terminal


3-37

Suggested Circuit Protection Specifications and Wire Size

In order to comply with most safety standards, some circuit protective devices should be used between the incoming three-phase power supply and the IMPULSE•VG+ Series 2. These devices can be thermal, magnetic, or molded-case breakers (MCCB); or “slow-blow”type fuses such as

“CCMR” or “J.”

C A U T I O N :

The following guidelines are only suggested values. Always conform to local electrical codes and wiring practices.


Input Fuse

Class

Molded/Case

Circuit Breaker


Power Circuit

Wiring

Control

Wiring Model #

230VClass

2006 -FVG+

2008 -FVG+

2011 -FVG+

2017 -FVG+

2025 -FVG+

2033 -FVG+

2054 -FVG+

2068 -FVG+

2080 -FVG+

2130 -FVG+

2160 -FVG+

2224 -FVG+

2300 -FVG+

460VClass

4001 -FVG+

4003 -FVG+

4005 -FVG+

4008 -FVG+

4011 -FVG+

4014 -FVG+

4021-FVG+

4028 -FVG+

4034 -FVG+

4041 -FVG+

4052-FVG+

4065 -FVG+

4080 -FVG+

4096 -FVG+

Drive

54

68

80

130

160

224

300

6

8

11

17.5

25

33

InputFuse

70

90

100

175

200

300

400

25

35

45

9

12

20

LPJ

LPJ

LPJ

LPJ

LPJ

LPJ

LPJ

CC

CC

CC

LPJ

LPJ

LPJ

100

100

175

250

300

450

600

40

60

70

15

20

25

34

41

52

65

80

96

1.9

3.6

5.1

8.5

11.7

14.8

21

28.6

45

60

70

90

100

125

20

25

30

40

3

6

8

15

LPJ

LPJ

LPJ

LPJ

LPJ

LPJ

CC

CC

LPJ

LPJ

CC

CC

CC

CC

80

80

125

125

150

200

25

30

50

60

10

10

15

20


3-38

12

10

10

12

12

12

6

4

4

1/0

1/0

4/0

2/0 x 2P

6

6

8

8

4

2

12

12

10

10

12

12

12

12

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

16/14

Ground

4

3

1

8

6

6

4

14/10

12/10

12/10

10

10/8

10/8

8

8

8

8

6

6

12/10

12/10

12/10

12/10

8

8

12/10

8/6

Model #

4128 -FVG+

4165 -FVG+

4224 -FVG+

4302 -FVG+

4450 -FVG+

4605 -FVG+

Drive

128

165

224

302

450

605


InputFuse

175

225

300

400

600

800

Input Fuse

Class

LPJ

LPJ

LPJ

LPJ

J

KRP-C

Molded/Case

Circuit Breaker

250

350

450

600

900

1450


Power Circuit

Wiring

1/0

2/0

4/0

2/0 x 2P

2/0 x 2P

250 MCM x 2P

Control

Wiring

16/14

16/14

16/14

16/14

16/14

16/14

Ground

3

1

4

4

1/0

1/0


3-39


c h a p t e r

4

Programming Basic Features


Overview

With its easy-to-use keypad and X-Press Programming, IMPULSE•VG+ Series 2 makes it easy to get up and running right away. In addition to explaining the keypad and X-Press Programming, this chapter explains how to view the scroll settings, get into the programming mode, and program speeds.

Checks Before Powering

After mounting and interconnections are completed, verify:

• Correct connections.

• Correct input power supply. (No voltage drop or imbalance, source kVA

≤

200, unless a line is used.)

WA R N I N G

DO not power 230V-rated drives with 460V power.

• No short circuit conditions.

• No loose screw terminals. (Check especially for loose wire clippings.)

• Proper load conditions.

Precautions

• Only start the motor if motor shaft rotation is stopped.

• Even with small loading, never use a motor whose nameplate amperage exceeds the inverter rated current.

DA N G E R

Braking method selection as shipped from Electromotive Systems is set for Decelerate to Stop command. Extreme caution should be used. If deceleration time is too long, equipment could run into endstop device, causing damage to equipment or injury to personnel.


4-3

Using the Keypad

With two 16-character lines available, the English keypad display makes it possible to view fault codes and change parameter settings. Parameter settings, with their parameter codes, are displayed in most cases. In addition, the parameter description is included on the top line of the display. The keypad enables you to:

• Program the various drive parameters.

• Monitor the functions of the drive.

• Read alpha-numeric fault-diagnostic indications.

• Operate the drive using the keypad (local operation).

WA R N I N G

Because of the additional potential hazards that are introduced when any drive is operated locally, we advise you to avoid operating it this way. If you do operate the drive locally, be aware that the crane or hoist will move when you press the RUN button. If you have questions, contact Electromotive Systems, Inc.

DRIVE FWD REV

SEQ

REMOTE

REF

MODE

SERVICE

IMPULSE

MENU ESC

JOG

DATA

ENTER

FWD

REV

RESET

STOP RUN


4-4

Keypad LED and Button Functions

Some of the keypad buttons, whose functions are described below, are dual-purpose. The dualpurpose keys have one function when used in a view-only mode, and another function when used in a programming mode.

DRIVE

This LED lights only when the drive is in the

Operation

mode

, which includes when the drive is first powered up.

FWD

This LED lights when the FORWARD command is given.

REV

SEQ

REMOTE

REF

MODE

SERVICE

MENU

ESC

This LED lights when the REVERSE command is given.

• The SEQ LED lights when selecting the RUN command from the control circuit terminals or serial communication.

• The REF LED lights when the Speed Reference is input through control circuit terminals or serial communication.

• Pressing this key toggles between the mode set-up display and the phone number for Electromotive Systems Service Department.

• Also toggles between REMOTE and LOCAL (Digital operator from keypad) operation when 02-1 is set to 1.

Displays to the Main Menu for mode selection.

Backs up to the previous display (before the DATA/ENTER key is depressed).

Jog run is enabled when local operation is selected.

JOG

Selects the next mode, parameter group, parameter function, parameter or parameter setting. It also increases the blinking digit of a parameter setting.

Selects the previous mode, parameter group, parameter function, parameter or parameter setting. It also decreases the blinking digit of a parameter setting.

RESET

DATA

ENTER

Selects the digit—from left to right—to be changed (indicated by blinking). It also resets the operation at faults.

Selects mode, group, function or parameter. Displays each parameter’s set value. By pressing this key again, the set value is entered.


4-5

FWD

REV

RUN

Selects forward or reverse run when LOCAL operation is selected.

• Pressing this key initiates run command when LOCAL operation is selected.

• The red LED lights steadily.

STOP

• Pressing this key initiates Base Block stop command.

• The red LED lights steadily when drive is at stop; blinks when Run command is active but output frequency reference is zero, off when drive output is controlling motor speed.

Parameters

There are hundreds of parameters that determine how the drive functions. These parameters are programmed in the drive’s software as measurable values or options—both of which will be referred to in this manual as settings. While some of these parameters are associated with one setting, others are tied to a number of possible settings.

NOTE: The terms “constant” and “parameter” have the same meaning.

Before shipping the drive to you, we programmed initial settings in the drive’s software so that most, if not all, of your crane system requirements are supported. However, if you do find it necessary to change the initial settings, we recommend that you only allow qualified crane system technicians to program the drive. This can be accomplished by using the

Password Barrier

and

Access Level

features. For more information on these security features, see Initialization Set-up on page 4-9.

You also have the option of allowing personnel with limited crane system knowledge to program only certain parameters—

User Parameters

—that you select. To select these parameters, see “User

Parameters (A2-XX)” on page 4-11.

Two other features to be aware of are

Initialize Parameters

(A1-05) and

User Defaults

(O2-03). Both these features are related and allow you to revert back to parameter settings that you save. This is especially helpful when you have made a number of programming changes, but want to get back to the settings you had before you made any changes. To program these features, see “Initilize

Parameters (A1-05)” and “User Defaults (02-03)” on page 4-11.


4-6

IMPULSE•VG+ Series 2 Structure of Parameters

Menu

Auto-Tuning

Programming

Modified parameters

Operation

Initialize

Group

Monitor

Initialize

Application

Special

Function

Tuning

Motor

Options

Terminal

Protection

Operator

Function

F2

F3

F4

F5

F6

F7

H1

H2

H3

H4

H5

L1

L3

L4

L6

L8

L9

O1

O2

O3

B3

B4

B5

B6

B7

B8

C1

U1

U2

U3

A1

A2

B1

B2

C2

C3

C4

C5

C6

C7

Monitor

Fault Trace

Fault History

Initialization Parameters

User-Defined Parameters

Preset References

Reference Limits

Sequence/Reference Source

Trim Control Level

Acceleration/Deceleration

Phase Loss Detection

SVR Function

Jump Frequencies

Quick Stop/Reverse Plug Simulation

Micro-Positioning Control Multiplier

Travel Limits

Zero Serv

Load Check

Ultra-Lift

Torque Limit

D5

D6

D8

D9

C8

C9

No Load Brake

G5IN4 Setup

C10 Weight Measurement

C11 Slack Cable Detection

D1

D2

D4

DC Injection

Automatic Slip Compensation

Automatic Speed Regulator Tuning

Torque Control

Droop Control

Dwell Function

S-Curve Acceleration/Deceleration

D10 Carrier Frequency

D12 Factory Tuning

E1

E2

E3

V/f Pattern 1

Motor Set-up

Motor 2 Method

E4

E5

F1

Motor 2 V/f Pattern

Motor 2 Set-up

Pulse Generator (PG) Option Set-up

Analog Input 14 Set-up

Digital Input Option Set-up

Analog Output Option Set-up

Digital Output 2 Set-up

Digital Output 8 Set-up

PG Output 36 Set-up

Digital Inputs - G5IF

Digital Outputs - G5OUT

Analog Inputs

Analog Outputs

Serial Communication Set-up

Motor Overload

Stall Prevention

Ref Detection

Torque Detection

Hardware Protection

Automatic Reset

Monitor Selection

Keypad Key Selection

Clear History


4-7

Parameter Modes

All parameters are organized under five modes:

Operation Mode

Drive operation is enabled. Drive status LED lights.

Initialize Mode

Parameter access levels, control method, motion, speed control mode, and passwords are selected.

Programming Mode

Parameters are set/read. Items to be set/read vary depending on the access level setting.

Auto-Tuning Mode

Motor parameters are automatically set by entering tuning data (motor nameplate values) when using open loop vector control method.

Modified Constants Mode

Only parameters that have been changed from the factory settings are set/read.


4-8

Initialization Set-up

Parameter Access Level (A1-01)

This parameter allows the “masking” of parameters according to user level. See the following table:

Setting

0

1

2

Description

Operation Only

User Program - Accesses parameters selected by OEM (A2-01 to A2-32).

Advanced Level - For advanced programming in special applications.

Refer to the parameter code table in Chapter 5 for available parameters at each level.

Control Method Selection (A1-02)

Select the control method best suited for your application.

Setting

3

Description

Flux Vector

NOTE: An auto-tune must be performed for all flux vector applications. Refer to the Auto-Tuning section on page 4-12.


4-9

Select Motion (A1-03)

Set this parameter to match the motion of application.

Setting

0

2

Description

Traverse - Decelerate to stop upon removal of RUN command.

No-Load Brake Hoist

Speed Reference (A1-04)

This parameter will automatically define the input terminals for the selections listed below.

Setting

0

1

4

5

6

2

3

Description

5-SPD Multi-step (default) — Defines Terminals 3-6 as speeds 2-5.

2-Step infinitely variable — Terminals 1 and 2 = b1-01 (Reference 1) and speed hold. Terminal 3 = Accelerate.

3-Step infinitely variable — Terminals 1 and 2 = b1-01 (Reference 1).

Terminal 3 = Speed Hold. Terminal 4 =Accelerate.

Uni-polar analog — Terminals 1 and 2 = A directional input. Terminal 13 = 0-

10V. Terminal 14 = 4-20mA.

Bi-polar analog — Terminal 13 = -10 to +10V. An input on Terminal 1 is required, but direction is determined by the reference given on Terminal 13.

2-SPD Multi-step — Defines Terminal 3 = 2nd speed.

3-SPD multi-step — Defines Terminals 3 and 4 as speeds 2 and 3 respectively.

Parameters Changed by X-Press Programming

Const#

A1-04

B1-01

B1-02

B1-03

B1-04

B1-05

B1-09

B1-10

H1-01

H1-02

H1-03

H1-04

H1-05

H1-06

Abbreviation

Speed Ref

Speed 1

Speed 2

Speed 3

Speed 4

Speed 5

JOG Speed

Ref Priority

Terminal 3 Sel

Terminal 4 Sel

Terminal 5 Sel

Terminal 6 Sel

Terminal 7 Sel

Terminal 8 Sel

5-Speed

M-Step

0

6.00

15.00

30.00

45.00

60.00

6.00

0

00

01

02

03

24

0E

2-Step Infinitely

Variable

1

6.00

15.00

30.00

45.00

60.00

6.00

0

05

07

09

13

24

0E

5-Step Infinitely

Variable

2

6.00

15.00

30.00

45.00

60.00

6.00

0

04

05

07

09

24

0E

Uni-Polar

Analog

3

6.00

15.00

30.00

45.00

60.00

6.00

1

07

09

13

16

24

0E

Bi-Polar

Analog

4

6.00

15.00

30.00

45.00

60.00

6.00

1

07

09

13

16

24

0E

2-Speed

M-Step

5

20.00

60.00

30.00

45.00

60.00

6.00

0

00

07

09

13

24

0E

3-Speed

M-Step

6

15.00

30.00

60.00

45.00

60.00

6.00

0

00

01

07

09

24

0E


4-10

Initial Parameters (A1-05)

Use this parameter to reset the inverter to its factory default settings.

Setting

0

1110

Description

No Initialization (factory default)

User Initialization - resets the inverter to user-specified initial values. To set user-specified initial values, make all required changes to parameter settings, then set 02-03 to “1”. The inverter will memorize all current settings as the user-specified initial values. Up to 50 changed parameters can be stored.

Password Entry (A1-06)

This parameter will enable the user to set a password that will inhibit the programming of the A1-01 to A1-03 parameters. This function is useful when used in conjunction with the access level parameter A1-01. To set the password, press the MENU and RESET buttons at the same time and the display will change from A1-06 to A1-07. Program in a password number, then when A1-06 is not the same as A1-07 parameter A1-01 to A1-03 cannot be changed. When A1-06 is the same as A1-

07, then A1-01 to A1-03 can be changed.

User Parameters (A2-01 through 30)

The user can select up to 30 parameters for quick-access programming. By setting the user access level (A1-01) to “User Program,” only the parameters selected in function A2 can be accessed by the user. To assign a parameter as a user parameter go to the A2 level in the initialize menu. Once the

A2 parameters are set and A1-01 is programmed to “User Program,” only the parameters visible in the program menu will be assigned to an A2 parameter.


4-11

Auto-Tuning

C AU T I O N

The brake output is not energized during auto-tune. The brake must be manually released and unreleased when Auto-Tuning is complete.

WA R N I N G

Auto-tuning should only be performed on a motor that is not coupled to a gearbox.

The IMPULSE•VG+ can adapt to all motors manufactured worldwide with it’s automatic tuning function. The inverter asks the user for minimal motor information, then guides the user through a quick simple tuning process. Refer to the Structure of Parameters on page 4-7 and the table below for the motor data required for automatic tuning.

NOTE: Contact Electromotive Systems service department if an auto-tune can not be performed.

Display

Rated Voltage

Rated Current

Rated Frequenc

Rated Speed

Number of Poles

Select Motor

PG Pulses/Rev

Description Default Setting

Sets motor rated voltage in VAC KVA dependent

Sets motor rated current in Amps KVA dependent

Sets motor rated frequency in Hertz 60.0 Hz

Sets motor rated speed in RPM

Sets the number of motor poles

Selects between motor 1 or 2

Sets encoder PPR

1750 RPM

4

1

1024 PPR

After scrolling through the tuning parameters using the Up Arrow key, depress the RUN key to begin auto-tuning. During tuning, “Tuning Proceeding” flashes on the digital operator display. When complete, “Tune Successful”, is displayed. Depress the Menu key to exit auto-tuning mode. Please refer to the “Fault Display and Corrective Actions at Auto-Tuning” section on page 6-11 if “Tune

Successful” is not displayed.

NOTE: If the STOP key is depressed during tuning, auto-tuning is interrrupted and the motor coasts to a stop. The data changed during tuning returns to its original values.

NOTE: If an auto-tune is unsuccessful, temporarily change D12-30=1 and D10-01 to at least

5.0KHz.


4-12

c h a p t e r

5

Programming Advanced

Features


Application

• B1 Preset References

• B2 Reference Limits

• B3 Sequence/Reference Source

• B4 Trim Control Level

• B5 Acceleration/Deceleration

• B6 Phase Loss Detection

• B8 Jump Frequencies

Preset Reference

Parmtr

Code

B1-01

B1-02

B1-03

B1-04

B1-05

B1-09

B1-10

Display

Reference 1

Reference 2

Reference 3

Reference 4

Reference 5

Jog Reference

Ref Priority

Function

Sets the frequency of

Minimum Speed/Speed 1.

Range

0.00–150.00 Hz

Sets the Speed 2 frequency.

0.00–150.00 Hz


0.00–150.00 Hz


0.00–150.00 Hz


0.00–150.00 Hz

0.00–150.00 Hz Jog Control and Inching

Control frequency reference.

Determines whether the digital or analog frequency reference is used.

0* Digital Ref Only

1* Analog Ref Only

2 Higher Ref Sel

* Changes automatically with A1-04 (Speed Reference).

0

30

60

45

60

6

Initial

Value

15

Adv

Adv

Adv

Adv

Adv

V/F

Access

Adv

Open

Loop

Vector

Access

Adv

Adv

Adv

Adv

Adv

Adv

Adv Adv


5-3

Reference Limits

When a run command is input and the frequency reference is less than the lower limit, operation discontinues. However, when the lower limit is set to less than the minimum output frequency (E1-

09), operation discontinues.

An alternate upper limit frequency can be used during operation when a Multi-Function Input (MFI) is set to 43 (Alt S-Ref UpLimit) and the MFI is on. Alternate Upper Limit Frequency = (B2-03)% x

(E1-04).

Parmtr

Code Display

B2-01 Ref Upper Limit

B2-02 Ref Lower Limit

B2-03 Upper Lim Gain

Function

Sets as a percentage of the maximum output frequency

(E1-04), which determines the maximum frequency at which the drive is able to run.

Range

0.0–110%

Sets as a percentage of the maximum output frequency

(E1-04), which determines the minimum frequency at which the drive is able to run.

A multiplier, sets an alternate upper limit frequency by a multifunction input = 43

0.0–109%

0–255%

2

100

Initial

Value

100

V/F

Access

Adv

Open

Loop

Vector

Access

Adv

Adv

Adv

Adv

Adv

Figure 5-1: Setting Frequency Upper and Lower Limits


5-4

Sequence/Reference Source

B3-01 and B3-02 determine the source from where the frequency reference and RUN command are generated.

Parmtr

Code

B3-01

B3-02

Display

Reference Source

0

1

2

3

Operator

Terminals

Serial Com

Option PCB

Run Source

Function

Source from where the frequency reference is generated.

Digital operator (Keypad).

Control circuit terminal

(G5IF card).

Serial communication

(Port 6CN).

Optional card (Port 2CN).

Source from where the

RUN command is generated.

Digital operator (Keypad).

0 Operator

1

2

Terminals

Serial Com

Control circuit terminal

(G5IF card).

Serial communication

(Port 6CN).

3 Option PCB

Optional card (Port 2CN).

* Changes automatically with A1-03 (Motion).

Range

Initial

Value

1

Access

Level

Adv

1 Adv

Ramp to Stop (B3-03=0)

Upon removal of the FWD or REV run command, the motor decelerates at a rate determined by the time set in deceleration time 1 (B5-02) and DC injection braking is applied after the minimum output frequency (E1-09) has been reached. If the deceleration time is set too short or the load inertia is large, an overvoltage fault (OV) may occur during deceleration. In this case, increase the deceleration time or install an optional braking transistor and/or braking resistor.

Braking torque: without braking resistor, approximately 20% of motor rated torque; with braking option, approximately 150% of motor rated torque.

Parmtr

Code

B3-03

Display

Stop Method

0 Ramp to Stop

(A1-03=0)

1 Coast to Stop

(A1-03=1)

Function

Determines stop method.

5 Hoist 2-Stop

6 No Load Brake (A1-03=2)

* Changes automatically with A1-03 (Motion)

Range

Initial

Value

*

Access

Level

Adv


5-5

Coast to Stop (B3-03=1)

Figure 5-2: Ramp to Stop

Figure 5-3: Coast to Stop


5-6

Hoist 2-Stop (B3-03=5)

Figure 5-4: Hoist 2-Stop

Zero-Speed Operation

This parameter sets the speed reference level at which Zero Speed mode operation will activate, in accordance with the selection programmed B3-05 (see the figures below).

Parmtr

Code

B3-05

Display

Zero-Speed Oper

0

1

RUN at Freq Ref

Stop

2 RUN at Min. Freq (E1-

09)

3 RUN at Zero RPM

Function

Operation Selection at Zero

Speed.

Operate according to the

Frequency Reference

Coast when the Frequency

Reference is below E1-09

Output the Frequency set in

E1-09

Zero reference value when the frequency reference is below

E1-09

Range Initial Value

0

Access

Level

Adv


5-7

Figure 5-5: ASR Output with Analog Input

When the Speed Reference input is an analog signal, Zero Speed mode operation over long.

B3-05: 0 Run at Frequency Reference

E1-09: (Minimum Output Frequency) ineffective

Figure 5-6: B3-05: 0 Run at Frequency Reference


5-8

B3-05: 1 STOP

E1-09: (Minimum Output Frequency) effective

Figure 5-7: B3-05: 1 STOP


5-9

B3-05: 2 Run at Minimum Frequency


Figure 5-8: B3-05: 2 Run at Minimum Frequency


5-10

B3-05: 3 Run at Zero RPM


Figure 5-9: B3-05: 3 Run at Zero RPM


5-11

Input Scan Time

B3-06 selects the microprocessor scan time for reading sequence input data from the control circuit terminals. Set B3-06 to “0” when a quicker response is needed from the control circuit terminal.

Parmtr

Code

B3-06

Display

# of Input Scans

0 2ms–2 scans

1 5ms–2 scans

Function

Selects the microprocessor scan time

Range

Initial

Value

1

V/F

Access

Adv

Open

Loop

Vector

Access

Adv

LOC/REM Run Select

If the run reference/speed reference are switched between serial mode and drive terminal mode, B3-

07 determines action after the switch.

Initial

Value

0

V/F

Access

Adv

Open

Loop

Vector

Access

Adv

Parmtr

Code

B3-07

Display

LOC/REM Run Sel

0 Cycle Extrn Run

1 Accep Extrn Run

Function

Determines action after switching Run/Speed reference source.

If the run command is present at the time when the Run/Speed reference source is switched, it requires the run command to be removed and then reapply the run command from the new source to resume the normal operation.

If the run command is present at the time when the Run/Speed reference source is switched, it does not require the run command from the new source to be removed. The normal operation will continue.

Range


5-12

Trim Control Level

The trim control level is valid when the trim control increase command (setting: 1C) or trim control decrease command (setting: 1D) is set for a multi-function input (H1-01 to H1-06).

If the trim control increase command is ON when a frequency reference is input on the analog input, the trim control level will be added to the analog frequency reference and then output as the output frequency. If the trim control decrease command is ON, the frequency reference will be decreased by the trim control level.

Parmtr

Code

B4-02

Display

Trim Control LVL

Function

Sets Trim Control speed level

Range

0–100%

Initial

Value

10

Access

Level

Adv

Set the trim control level as a percentage of the maximum output frequency.

If the frequency reference minus the trim control level is less than zero, the output frequency will be zero.

Refer to the description of Multi-function Inputs (H1) for details on the trim control increase and trim control decrease commands.


5-13

Acceleration/Deceleration

Acceleration time sets the time necessary for the output frequency to accelerate from 0Hz to maximum output frequency (E1-04). Deceleration time sets the time necessary for the output frequency to decelerate from the maximum output frequency (E1-04) to 0Hz.

Parmtr

Code

B5-01

B5-02

B5-03

Display

Accel Time 1

Decel Time 1

Accel Time 2

B5-04 Decel Time 2

Function

Sets acceleration time.

Sets deceleration time.

Sets alternate accel. time.

Enabled by multifunction input=1B.

Sets alternate decel. time.

Enabled by multi-function input=1B.

Range

Initial

Value

0.0–25.5 sec 3.5

0.0–25.5 sec 2.5

0.0–25.5 sec 1.0

0.0–25.5 sec 1.0

Access

Level

Adv

Adv

Adv

Adv

NOTE: Assume the constant B3-03 is set to “0” (Ramp to Stop).

Figure 5-10: Normal Accel/Decel Time and Multiple Accel/Decel Changeover


5-14

Accel/Decel Time Switching Frequency

Accel/Decel times can be changed automatically without using multi-function inputs. When multifunction contact inputs are set for Accel/Decel selection, this command has priority over automatic change of Accel/Decel.

Parmtr

Code

B5-05

B5-06

B5-07

B5-08

B5-09

B5-10

B5-11

Display

Accel Time N Chg

Dec Time N Chg

Hoist 2 Stop

Fault Stop Time

Acc/Dec Units

Function

Sets acceleration time at

Speed Switch frequency.

Range

0.0–25.5 sec

Sets deceleration time at

Speed Switch frequency.

Sets deceleration time for

DOWN/REVERSE direction, when B3-03=5 (Hoist 2-

Stop).

Sets decel time to complete rest at STOP.

0.0–25.5 sec

0.0–25.5 sec

0.0–25.5 sec

Determines acceleration and deceleration time interval and range.

0 0.01sec for 0.00–2.55 sec

1 0.1sec for 0.0–25.5

Acc/Dec SW Freq

SW Freq Compare

0

1 lower SW Freq upper SW Freq

Determines acceleration/ deceleration switching level

0.0–150.0Hz

Determines when

Acceleration Time and

Deceleration Time at Speed

Switch Hz is enabled;

0: B5-05/06 is enabled, N-out

≤

B5-10

1: B5-05/06 is enabled, N-out

≥

B5-10

Initial Value

1.0

Access

Level

Adv

1.0

0.3

Adv

Adv

0.3

1

120.0

1

Adv

Adv

Adv

Adv


5-15

Figure 5-11: When B5-11=1 (Upper Switch Frequency)

Figure 5-12: B5-11=0 (Lower Switch Frequency)

Figure 5-13: B5-07 = 3 (Hoist 2-Stop)


5-16

Torque Limit Accel/Decel

Determines Accel/Decel times when the multi-function input H1-01~H1-06 = 14 (Torque Limit

Accel/Decel) is on.

Parmtr

Code

B5-12

Display

For T Lim Accel

B5-13 For T Lim Decel

B5-14 Rev T Lim Accel

B5-15 Rev T Lim Decel

Function

Determines acceleration time at FORWARD when Torque

Limit Acc/Dec is multifunction input = 14.

Range

0.0–25.5 sec

Determines deceleration time at FORWARD when Torque


0.0–25.5 sec

Determines acceleration time at REVERSE when Torque


Determines deceleration time at REVERSE when Torque


0.0–25.5 sec

0.0–25.5 sec

Initial Value

0

0

0.5

0

Access

Level

Adv

Adv

Adv

Adv


5-17

Phase Loss Detection

Input Phase Loss Detection is provided to protect the main power rectifiers and capacitors in the

IMPULSE•VG+ Series 2. If any of the three-phase input lines are lost, the DC Bus capacitors and rectifiers suffer approximately a 40% increase in current. This increase will cause a ripple on the DC

Bus voltage. If this ripple becomes too great, the drive automatically shuts down and displays a fault code “PF”.

Phase Loss Detection compares the output current of each of the three phases to a preset level. If the output current of any of the phase falls below the preset level, a “LF” fault will appear on the display.

The drive will immediately set the brake, thus retaining control of the load.

Parmtr

Code

B6-01

Display

Ph Loss In Sel

B6-02

B6-03

0 Disabled

1 Enabled

Ph Loss In Lvl

Ph Loss Out Sel

B6-04

B7-01

0 Disabled

1 Enabled

Ph Loss Out Lvl

SVR Delay Timer

Function

Determines whether Phase

Loss Detection Input is enabled.

Range

Initial

Value

0

Access

Level

Adv

Determines Phase Loss

Detection Input Level.

Determines whether Phase

Loss Detection Output is enabled.

0.0–25.5% 7.5

1

Determines Phase Loss

Detection Output level.

“Noisy” Encoder Signal

Detection

0.0–20.0%

0–2000ms

5.0

70

Adv

Adv

Adv

Adv


5-18

Jump Frequencies

This function allows the “jumping” of critical frequencies so that the motor can operate without resonant vibrations caused by some machine systems. This function is also used for deadband control. Setting the value to 0.0 Hz disables this function.

Parmtr

Code

B8-01

Display

Jump Freq 1

B8-02 Jump Freq 2

B8-03 Jump Freq 3

B8-04 Jump Bandwidth

Function

First of three jump frequencies; part of Jump

Bandwidth.

Second of three jump frequencies; part of Jump

Bandwidth.

Range

0.0–150.0 Hz

0.0–150.0 Hz

Initial

Value

0

0

Third of three jump frequencies; part of Jump

Bandwidth.

Jump frequency reference bandwidth; combines

Jump Frequencies 1, 2, and

3.

0.0–150.0 Hz

0.0–20.0 Hz

0

1.0

Access

Level

Adv

Adv

Adv

Adv

Figure 5-14: Jump Frequencies


5-19

Special Functions

• C1 Quick Stop/Reverse Plug Simulation

• C2 Micro-Positioning Control Multiplier

• C3 End of Travel Limit

• C4 Zero Servo

• C5 Load Check

• C6 Ultra-Lift

• C7 Torque Limit

• C8 No Load Brake

• C9 G5IN4 Setup

• C10 Weight Measurement

• C11 Slack Cable Detection

Special Function

C1: Quick Stop/Reverse Plug Simulation

C2: Micro Positioning

C3: End of Travel Limits

C4: Zero Servo

C5: Load Check

C6: Ultra Lift

C7: Torque Limit

C8: No-Load Brake Hoist

C9: G5IN4 Setup

C10: Weight Measurement

C11: Slack Cable Detection

Traverse (A1-03=0)

Yes

Yes

Yes

Yes

No

No

Yes

No

Yes

No

No

Motion (A1-03)

No-Load Brake (A1-03=2)

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes


5-20

Quick Stop™/Reverse Plug Simulation™

The Quick Stop Function provides an automatic Alternate Deceleration at Stop Command.

NOTE: The Quick Stop Deceleration time differs from the normal deceleration time and is applied only when the RUN command is removed.

Parmtr

Code

C1-01

Display

Quick Stop 0/1

C1-02

0 Disabled

1 Enabled

Quick Stop Time

Function

Determines whether Quick

Stop is enabled


0

Access

Level

Adv

Deceleration time during

Quick Stop function.

0.0–25.5 sec 0.5

Adv

Figure 5-15: Quick Stop


5-21

The Reverse Plug Simulation provides an automatic alternate deceleration time/acceleration time at a change direction command. The deceleration time and the acceleration time are set independently of the normal acceleration and deceleration times.

Parmtr

Code Display

C1-03 Reverse Plug 0/1

0 Disabled

1 Enabled

C1-04 RevPlg

C1-05 RevPlg

Function

Determines whether

Reverse Plug Simulation is enabled.

Range

Initial

Value

0

Access

Level

Adv

Deceleration time during

Reverse Plug Simuation.

Acceleration time during

Reverse Plug Simulation

0.0–25.5 sec 1.0

0.0–25.5 sec 1.0

Adv

Adv

Figure 5-16: Reverse Plug Simulation


5-22

Micro-Positioning Control™

Micro-Positioning Control function can provide 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. MS Gain 1 (C2-01) and MS Gain 2 (C2-

02). They can be adjusted and enabled independently.

Parmtr

Code

C2-01

Display

MS Gain 1

C2-02 MS Gain 2

Function

For Micro-Positioning

Control–the number multiplied by the Analog or

Digital Speed Reference to achieve slow-speed operation.

For Micro-Positioning

Control–an alternate number multiplied by the

Analog or Digital Speed

Reference to achieve slowspeed operation.

Range

0.00–2.55

0.00–2.55

Initial Value

1.00

1.00

Access

Level

Adv

Adv

Figure 5-17: Micro-Positioning Control

NOTE: If both Micro-Speed 1 and Micro-Speed 2 are enabled. Micro-Speed 1 always takes higher priority over Micro-Speed 2.


5-23

Travel Limits

This function can automatically slow and stop a crane or hoist when it reaches the MS travel limits.

Two types of limit inputs (slowdown and stop) are available in both travel directions. Inputs can be programmed through either G5IF and G5IN4 cards.

Parmtr

Code

C3-01

C3-02

C3-03

C3-04

C3-05

C3-06

C3-07

Display

Up Limit 1 Speed

UL 1 Decel Time

UL 2 Stop Time

Low Limit 1 Speed

LL 1 Decel Time

LL 2 Stop Time

Upper Action

0 Decel to Stop

1 BB to Stop

Function Range

Speed at Upper Limit input..

0–150 Hz

0.0–25.5 sec Decel time to Upper Limit

Speed.

Decel time to STOP when

Upper Limit is Input..

0.0–25.5 sec

Speed at Lower Limit input..

0–150 Hz

Decel time to Lower Limit

Speed

0.0–25.5 sec

0.0–25.5 sec Decel time to STOP when

Lower Limit is input.

Determine the stop method at

Upper Limit 2 Input.

0.5

6

1.0

Initial Value

6

1.0

Access

Level

Adv

Adv

0.5

0

Adv

Adv

Adv

Adv

Adv

Figure 5-18: Upper Limit (UL1)


5-24

Figure 5-19: Upper Limit 2 (UL2)

Figure 5-20: Lower Limit 1 (LL1)

Figure 5-21: Lower Limit 2 (LL2)


5-25

Zero Servo

When Zero Servo is enabled, it maintains the motor shaft at a stationary positon. This function is enabled by a MFI (Mulit-Function Input) that is programmed as the digital input code #3A H1-

01~06=3A.

Parmtr

Code

C4-01

Display

Zero Servo Timer

Function Range

Maximum duration of Zero

Servo action at multi-function input.

0–255 sec

Zero Servo multiplier.

0–100

Initial Value

10

Access

Level

Adv

C4-02 Zero Servo Gain * Adv

C4-03 Zero Servo Count Zero Servo completion width. 0–16383 5 Adv

* For drive model #s 2006-2054 and 4003-4021 the Initial Value is 25. For drive model #s 2068-2300 and 4028-4605 the Initial Value is 50.

Figure 5-22: Zero Servo


5-26

Load Check

Load Check function is a load-limiting feature that ensures the programmed load limit of the hoist is not exceeded. It prevents the lifting (and potential loss) of a load that is overweight. When

IMPULSE•VG+ Series 2 detects an overload condition, it prevents any further raising. However, the load can be lowered at the speed that is specified by constant C5-14 (Load Check Fault speeds).

Function

Determines whether Load

Check is enabled.


0

Access

Level

Adv

Parmtr

Code

C5-01

C5-02

Display

Load Check 0/1

0 Disabled

1 Enabled

LC Alarm Action

C5-03

0 Alarm Only

1 Decel to Stop

2 Coast to Stop

3 Fault Stop

Min Torque Ref

C5-04

C5-06

C5-07

C5-09

C5-11

Look Speed 1

Vec Torque Ref

Look Speed 2

Look Speed 3

1 Ref for > LS 3

C5-12 LC Setting Time

C5-13 LC Test Time

C5-14 LC Fault Speed

Action at Load Check alarm or fault. “BB to Stop” is

Immediate Stop at STOP.

2

Minimum current/torque reference during acceleration that triggers Load Check.

First Load Check frequency reference.

Torque reference at LS1, 2 and 3.

0–100%

0–150 Hz

0–300%

Second Load Check frequency reference.

Third Load Check frequency reference.

0–150 Hz

0–150 Hz

Load Check Current when

Output Frequency > Look

Speed 3.

Time for holding Output

Frequency to stabilize Output

Current.

Time (after the LC Setting

Time) for comparing Output

Current with Reference

Current

30–200%

0–2.55 sec

0–2.55 sec

Maximum lowing speed after

Load Check fault

0–255 Hz 6

60

20

60

6

125

160

0.20

0.10

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv


5-27

Figure 5-23: Load Check

Figure 5-24: Example of Operation C5-02=2


5-28

Ultra-Lift

Ultra-Lift provides additional productivity by allowing a crane or hoist to quickly move into position. The feature enables the motor to over speed when the load is less than 100 percent of the rated capacity. Ultra-Lift determines the torque required for the load, calculates the maximum safe speed, and automatically accelerates to this speed. However, the maximum speed cannot exceed the lesser value of the Ultra-Lift Maximum Output Frequency-RAISE (C6-02), Ultra-Lift Maximum

Output Frequency-LOWER (C6-03), and Maximum Frequency (E1-04).

NOTE: Note: Ultra-Lift is disabled when in traverse applications or in the reverse direction.

Maximum Frequency (E1-04) must be > the higher value between C6-02 and C6-03.

Parmtr

Code

C6-01

Display

Ultra Lift 0/1

C6-02

0 Disabled

1 Enabled Automatic

2 Enabled by MFI

Ultra Lift ForSpd

C6-03

C6-04

C6-05

C6-06

C6-07

C6-08

Ultra Lift RevSpd

Ultra Lift For T

Ultra Lift Rev T

UL Enabling Spd

UL Delay Time

SFS Acc Gain

Function

Determines whether Ultra

Lift is enabled.

Range

Initial

Value

0

Maximum Output

Frequency during Ultra

Lift—FORWARD.

Maximum Output

Frequency during Ultra

Lift—REVERSE.

Maximum output torque below which Ultra Lift—

FORWARD is enabled.

0–150 Hz

0–150 Hz

0–100%

60

60

50

Maximum output torque below which enabled Ultra

Lift REVERSE.

Threshold frequency at which Ultra Lift is enabled.

0–255%

0–150 Hz

Delay time at enabling speed prior to torquecompare function.

30

60

0.0–30.0 sec 2.0

Speed feedback acceleration multiplier.

0.1–9.9

1.0

V/F

Access

Adv

Open

Loop

Vector

Access

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv


5-29

Enable Ultra-Lift Function:

2,3,5-Speed Multi-Step (A1-04=0, 5, or 6):

1. Set C6-01=1 or 2 to enable the

Ultra-Lift Function

, 1= Enable Automatic, 2= Enable by Multi-

Function Input (MFI).

2. Set C6-02 and C6-03 to determine

Ultra-Lift

maximum FOR/REV output frequency.

3. Set C6-04 and C6-05 to determine

Ultra-Lift

maximum enable output current.

4. Set the

Ultra-Lift Enabling Speed

(C6-06) one or two hertz below the maximum normal running speed reference.

For example: If the maximum normal running speed is at 60 Hz, set C6-06 to 59 Hz

or 58 Hz as the

Ultra-Lift Enabling Speed

.

5. Ensure that the

Maximum Frequency (E1-04)

is increased from 60 Hz.

2, 3 Step Infinitely Variable (A1-04=1 or 2)

6. If the system is using

2-Step or 3-Step Infinitely Variable

as the

Speed Control Method

, the following formula is used to adjust the constant

B2-01

(Reference Upper Limit).

B2-01=60 Hz x 100 / E1-04

Bi-Polar/Uni-Polar Analog (A1-04=3 or 4)

7. If the system is using

Bi-Polar Analog

or

Uni-Polar Analog

as the

Speed Control Method

, the following formula is used to adjust the constant

H3-02

(Gain Multiplier for Terminal 13 analog input signal).

H3-02=60 Hz x 100 / E1-04

W A R N I N G

Motors and drive machinery must be capable of operating above motor base speed. Consult the motor/gearbox/hoist manufacturer before enabling Swift Lift function. Failure to observe this warning may result in damage to equipment and possible injury or death to personnel.


5-30

Torque Limit

IMPULSE•VG+ Series 2 dynamically controls the torque output of the motor at all times. The

Torque Limit Function limits the amount of motor torque on all four quardrants of vector control operation:

• Forward Motoring

• Reverse Motoring

• Forward Regenerating

• Reverse Regenerating

Parmtr

Code

C7-01

C7-02

C7-03

C7-04

C7-07

Display

Torque Limit Fwd

Torque Limit Rev

Torq Lmt Rgn

Torq Limit Rev Rgn

T-Lim Gain MFI

Function

FORWARD torque limit

REVERSE torque limit

Regenerative torque limit at

FORWARD

Regenerative torque limit at

REVERSE

Used when H1-01~H1-06 =

15 and MFI is on

Range

0–300%

0–300%

0–300%

0–300%

0–2.55

Initial Value

150

150

180

Access

Level

Adv

Adv

Adv

180

1.25

Adv

Adv

No-Load Brake Start/Stop

The No-Load Brake Hoist mode provides a special start/stop sequence designed specifically for No-

Load Brake Hoists. This mode is enabled automatically when the Motion is set to NLB Hoist (A1-

03=2). This will also automatically set the Stopping Method to No-Load Brake (B3-03 = 6).

The NLB Sequence is comprised of a series of Timers and Counters that monitor certain feedback devices. The sequence is divided into two parts, NLB Start and NLB Stop.

The NLB Start Sequence begins by building up torque in the motor to a predefined level within the

C8-01 (Torque Compensation Time) timer. This level is determined by several factors which are defined below. During the C8-01 time, the drive is monitoring current to motor. The internal current feedback equation must be satisfied within the time set in C8-02 (IFB OK Time). If it is not, a BE2 (No-Current) alarm will be displayed on the Keypad.

Factor 1: On the first run command after power up, or after any major fault which causes the NLB

Stop sequence to be skipped, the NLB Start sequence by default looks at the value programmed in

C8-16, the Initial Brake Release torque.

Factor 2: Once the system has completed a successful NLB Start and NLB Stop, a new value is used.

This value is one that has been memorized and stored into memory during the NLB Stop Sequence.

It is equivalent to the amount of torque required for the motor to hold the load that is on the hook in

Zero Servo (otherwise known as Load Float) with the brake released. Some benefits of memorized

Load Float torque for the next brake release are:

• Faster response to run commands when drive is in Base Block Status.

• Upon brake release, shaft rotation begins in the direction of the run command.


5-31

If the memorized value is less than the programmed value in C8-03 (Minimum Brake Release torque), then C8-03 is used as the next brake release value. If the feature must be disabled, C8-03 and C8-16 should be set to equal values of approximately 100 %.

Once the brake has been commanded to release, the drive frequency output remains at zero for the amount of time programmed into C8-04. During C8-04, the drive waits for the brake to completely open and watches encoder feedback. If the amount of feedback is less than the setting in C8-05 (Roll

Back Count), then the drive proceeds to the BE3 check. If it is not, a BE1 alarm is displayed on the keypad. For the BE3 check, if the brake opened mechanically, then the encoder feedback must be greater than or equal to the value programed in C8-07 (BE3 Detect Count) within the time set in C8-

06 (BE3/Alternate Torque Time). If it is not, then BE3 is displayed. By the time the drive has completed the BE3 check, there should be a significant amount of motor shaft movement and the

NLB start sequence is complete.

The NLB 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 Zero Servo position or more commonly referred to as Load Float for the duration of C8-10 (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 NLB Start Sequence entirely. The Load Float Timer is reset after each new run command. Once the Load Float Timer expires, the brake output command is removed (thereby closing the brake) and Zero Servo is maintained for the time set in

C8-11 (Brake Delay Time) to allow the brake to fully close. Once the Brake Delay Time has expired, the BE6 check is executed. The BE6 check simply monitors encoder feedback and compares it to C8-13 (BE6 Max count). The encoder feedback must not exceed the number of counts in C8-13 within the C8-12 (BE6 Detect Timer) time. If it does (meaning the load slipped through the brake), a BE6 alarm is displayed on the keypad and the drive will reset its zero servo position and maintain its new position. Run commands will still be accepted with the exception of a reduced speed in the up direction set by C8-17 (BE6 Up speed) and the NLB stop sequence will begin again once the run command had been removed.

NOTE: All of the above faults are annunciated by a digital output which is preprogramed by

Electromotive Systems to output to terminal 2 on the G5OUT card. A customer supplied warning device may be connected to this output to notify operators of potentially hazardous brake conditions. BE6 detection is disabled (C8-12=0) when the inverter leaves the factory.

Electromotive Systems does not recommend enabling BE6 detection without the use of an audible or visual alarm to signal an operator of a hazardous condition. If BE6 detection is desired, a warning device should be installed and wired to terminal 2 of the G5OUT card (see

Fig. 3-35 for wiring details). If the alarm activates upon removing the run command and the stopping sequence is intitiated, DO NOT turn off power. This fault means the brake has failed and the motor/drive combination is holding the load. In this situation, move the crane to a safe location and remove the load from the hook. Corrective action should then be taken. See page

6-5.

W A R N I N G

DO NOT turn off power to the drive during a BE6 fault. This may result in loss of control of the load if the brake has failed in the open position or is unable to hold the load.

To enable BE6 detection, C8-12 must be greater than 0. C8-12=2.0 seconds is the recommended

BE6 detect time. For more information on BE6 detection, reference Fig. 5-29, No Load Brake BE6 timing diagram.


5-32

Parmtr

Code

C8-01

C8-02

C8-03

C8-04

C8-05

Display

Torq Comp Time

IFB OK Timer

Brake Rel Torq

Roll Back Timer

Roll Back Count

Function

Time for torque to build to

300% at start.

Time period during which

Output Current must be OK.

Minimum brake release torque.

Range

0.00–2.55 sec

0.00–2.55 sec

0–300%

Time period during which the roll back is checked.

0.00–2.55 sec

Detection counts for excessive roll back.

0–16536

Initial Value

*

*

10

0.50

400

Access

Level

Adv

Adv

Adv

Adv

Adv

C8-06

C8-07

C8-08

RE3/Alt Torq T

BE3 Det Count

Alt Rev T Limit

Time period during which C8-

07 is measured.

0.00–2.55 sec

Detection count for Encoder/

Seized-Brake Fault (BE3). It is the encoder pulse count, during the time period of C8-

06, below which the BE3 fault triggered.

0–16536

For a LOWER command in the NLB Hoist Motion Mode only—Torque limit for time of C8-06 to prevent driving through a brake that has failed closed.

0–100%

0.50

50

10

Adv

Adv

Adv

C8-09

C8-10

C8-11

C8-12

Zero Speed Level

Load Float Time

Brake Delay Time

BE6 Detect Timer

Determines speed reference at which Zero-Speed Level activates.

0–150 Hz

After stop command time period during which the load is held at the zero-position and the electric brake is not set.

255 sec

The delay time between

Immediate Stop at STOP and

Brake Set.*

Time period during which the electric brake is set and tested for sustaining the load.

0.00–25.5 sec

0.00–25.5 sec

2

10

0.7

0

Adv

Adv

Adv

Adv

C8-13

C8-15

C8-16

BE6 Max Count

Load Float Ext. T

Init Brk Release

Total pulse counts must be

<C8-13, during C8-12, otherwise BE6 Fault.

Load Float extention time enabled MFI=46.

0–16536 pulses

0–255sec

Brake release torque at power up and after UL2, LL2, EF faults or MFI’s which cause the output to base block.

0-300%

50

10

100

Adv

Adv

Adv

C8-17 BE6 Up Speed Maximum up speed after BE6 is detected.

0-30 Hz 6.00

Adv

* For drive model #s 2006-2054 and 4003-4021 the Initial Value is 1.5. For drive model #s 2068-2300 and 4028-4605 the Initial Value is 2.5.


5-33

BE4

BE5

BE6

BE7

Fault Code

BE0

BE1

BE2

BE3

No-Load Brake Sequence Faults

Fault or Indicator Name/Description

Brake Answer-Back Fault. During RUN, Brake Answer-Back is lost.

Input from brake contactor or brake limit switch has been disconnected for more than 500 msec.

Torque-Proving Fault. At START, pulse feedback, after brake release, is greater than C8-05 count. There is excessive roll-back at start.

Current-Proving Fault. At START for Torque Proving Sequence only-

Current (IFB has not reached predetermined setting within C8-02 time at START.

Brake Release Fault. For Brake Release-Check Sequence only-Pulse feedback is less than C8-07 counts. After electric brake release command is output-Electric brake is not released.

Brake Answer-Back Fault. At Start, Brake Anwer-back is not input within C8-04 time.

Brake Answer-Back Fault. At Stop, Brake Answer-back signal is not removed within C8-11 time.

Brake Set Fault. At Stop, Brake Proving Sequence only–Pulse feedback after brake command removed, is greater than C8-13 count-

Excessive movement through brake at stop.

Brake Answer-Back Fault. At Power Up, Brake Answer-back is on-

Electric brake not closed.


5-39

Optional Digital Input Set-up (G5IN4 Digital Multi-Function Inputs)

Parmtr

Code

C9-01

Display

G5IN4 0/1

C9-02

0 Disabled

1 Enabled

G5IN4 Setup

Function

Determines whether the

G5IN4 Digital Multi-

Function Inputs are enabled.


0

Access

Level

Adv

Determines the four settings for G5IN4 Digital Multi-

Function Inputs.

0000–FFFF 0000 Adv

The optional G5IN4 board accepts four additional multi-function inputs. The G5IN4 board has four terminals, each of which can be programmed to one of the fourteen sets of inputs. Each input in the set can be enabled or disabled.

1. Set C9-01 to 1.

2. Determine the parameter C9-02 setting by specifying the first digit (from left) and the fourth digit (from left) using table 5.1 and 5.2. The second and third digit should always be “0”.

3. Set parameter C9-02.

1 = 120V is present on terminal

0 = No voltage is present on terminal

MONITOR

U1-25

1

2

5

6

3

4

7

1

0

1

0

1

1

1

0

0

1

1

0

1

2

0

1

TERMINAL

1

1

0

1

1

3

0

0


5-40

0

0

0

0

0

4

0

0

MONITOR

E

F

C

D

A

B

8

9

0

1

0

1

0

1

0

1

1

1

0

0

1

1

0

0

TERMINAL

1

1

1

1

0

0

0

0

1

1

1

1

1

1

1

1

Table 5.1: G5IN4 Digital Multi-Function Input Sets (1 through E)

Multi-Function Input Assigned to Each Terminal

Terminal 1

Upper Limit—SLOW

DOWN; Normally Closed

Upper Limit—SLOW

DOWN; Normally Open

Upper Limit STOP;

Normally Closed

Upper Limit STOP;

Normally Open

Upper Limit STOP;

Normally Closed

Upper Limit STOP;

Normally Open

Upper Limit STOP;

Normally Closed

Upper Limit STOP;

Normally Closed

Upper Limit STOP;

Normally Closed

Upper Limit STOP;

Normally Closed

Swift-Lift Enable

Alternate Torque Limit

Zero Servo Command

Alternate Speed Reference

Upper Limit

Terminal 2 Terminal 3

Upper Limit STOP;

Normally Closed

Upper Limit STOP;

Normally Open

Lower Limit STOP;

Normally Closed

Lower Limit STOP;

Normally Open

Lower Limit STOP;

Normally Closed

Lower Limit STOP;

Normally Open

Lower Limit STOP;

Normally Closed

Lower Limit STOP;

Normally Closed

Lower Limit SLOW;

Normally Closed

Lower Limit SLOW;

Normally Open

Micro-Positioning Control

Multiplier 1


Multiplier 1


Multiplier 1


Multiplier 1


Multiplier 1


Multiplier 1

Lower Limit STOP;

Normally Closed

Lower Limit STOP;

Normally Closed

Torque Limit Acceleration/

Deceleration

Torque Limit

Acceleration/Deceleration


Multiplier 1


Multiplier 1


Multiplier 1


Multiplier 1

Load Float Time Extension Micro-Positioning Control

Multiplier 1

Serial/Inverter Command

Changeover


Multiplier 1

Terminal 4

Lower Limit STOP;

Normally Closed

Lower Limit STOP;

Normally Open


Multiplier 2


Multiplier 2

Swift-Lift Enable

Swift-Lift Enable


Deceleration


Deceleration

Zero Servo Command

Weight Measurement

Command


Multiplier 2

Upper Limit SLOW;

Normally Closed


Multiplier 2


First Digit (From

Left) You Enter

1

2

3

4

5

6

7

8

9

A

B

C

D

E


5-41

Input for

Terminal 1

E

D

E

D

E

D

E

D

E

D

E

D

E

D

E

Key

Enable = E

Disable = D

Table 5.2: Enabling/Disabling Decision Table for C9-02

Input for

Terminal 2

D

E

E

E

D

D

E

E

D

D

E

E

D

D

E

Input for

Terminal 3

E

E

E

D

E

D

D

E

D

E

E

D

E

D

D

Input for

Terminal 4

E

E

E

E

E

E

E

D

E

D

D

D

D

D

D

Fourth Digit (From

Left) You Enter

D

E

F

B

C

9

A

7

8

5

6

3

4

1

2


5-42

Weight Measurement

The IMPULSE•VG+ Series 2 offers Weight Measurement Function for the hoist applications. The

Weight Measurement function can be enabled automatically or manually. The load weights can be displayed by the constant U1-29 on the keypad or by an external device through the analog output terminals.

Parmtr

Code

C10-01

C10-02

C10-03

C10-04

Display

Load Weight 0/1

0 Disabled

1 Enabled at C5-04

2 Enabled at MFI

3 Both Auto & MFI

TRO Pri Delay

LW Display Hold

0 Hold Display

1 Hold Disp 3 sec

LW Conversion

C10-05 Full Load TRO

C10-06 No Load TRO

C10-07 Line 2 Display

0 tons

1 pounds

2 kilograms

3 metric tons

4 percent Rload

H1-01~06 Terminal 3~8 = 44

Function

Determines whether Load

Weight is enabled.

Range

Weight Measurement enable by Multi-Function Input.

Initial Value

0

Access

Level

Adv

Torque Output Calculation primary delay time.

0–1000 msec 200

0

Until next run command is on

Multiplier of torque output calculation for display. Data is n0000, so multiplier is

10000; “n” is decimal point.

Precentage of Torque Output that is defined as Full-Load

Torque Output.

Percentage of Torque Output that is defined as No-Load

Torque Output.

Determines “weight” measurement units in which the parameter settings will be expressed. The unit abbreviations appear on line 2 of the display

00000–39999

0.0–200.0%

0.0–200.0%

0

100

0

0

Adv

Adv

Adv

Adv

Adv

Adv

Adv

NOTE:

The Weight Measurement Function only works during the forward motion (lifting).


5-43

Setup Procedures

System Tare:

Attach all of the under hook attachments that are required during normal lifting, i.e. chains. Run the hoist motor at 30 Hz. Record the Torque reference value by monitoring U1-09 during at constant speed. For better acuracy, repeat the above operation several times and calculate the average torque reference value. Enter the average value at C10-06 (no load torque reference).

Figure 5-30: System Tare

K: C10-04 multiplier of torque output calculation for display. The display data is Nxxxx.

“N” is the decimal points. xxxx four digits are multiplier.

Example: C10-04=10050

→

K

IW

=50

System Calibration

The following is a example of system calibration.

Set

C10-01=2

C10-02=700ms

C10-03=1

C10-04=K

1

C10-05=100%

C10-06=U1-09

C10-07=0

H1-06=44

Enabled at MFI

TRO Calculation primary Delay Time

Hold Display for 3 seconds

Multiplier of TRO Calculation for Display

Full Load Torque Output

No Load Torque Output obtained for system tare

Display Units; tons

Weight measurement enabled by MFI


5-44

1. Calculate K

1

as indicated below

K

1

=

WRL

100-(C10-06) x100

2. Enter the K

1

value for the parameter C10-04.

3. Place a known weight that is equal or less than the rated load, to the hoist.

4. Run the hoist at 6Hz and take a reading value of W1 (U1-29). Repeat above step serveral times to obtain an average of W

1

(U1-29).

5. Compare W

1

to WRL. If the difference between W and WRL is greater than 5%, calculate K

2

as indicated below.

K

2

=

WRL

W

1

(U1-29) x K i

6. Replace K

1

and K

2

by setting C10-04=K

2

.

7. Repeat steps 4 and 5 until the difference between W

1

(U1-29) and WRL is less than 5%.

WRL = Weights at 100% rated load.

W = Weights that are displayed by U1-29.

K = Multiplier (C10-04).

Figure 5-31: Load vs. Torque


5-45

Slack Cable Detection

IMPULSE•VG+ Series 2 offers Slack Cable Detection in the hoist application. The Slack Cable condition is detected when the torque output is drastically reduced and has dipped below a set-point

(C11-03) level. When Slack Cable condition occurs, the output action is defined by the C11-02 which has 6 selections.

The Slack Cable Detection is not executed, unless both of the following conditions are true:

• The output frequency is between C11-04 and C11-06.

• The Slack Cable Detection delay time is between C11-05 and C11-07.

Setup Procedure:

• To set the Slack Cable Detection torque level (C11-03), by lowering the hoist without load at a constant speed that the hoist would normally run during the operation. Monitor and record the torque reference (U1-09). Repeat above operation several times to ensure an accurate reading.

• Then Set C11-03 = [(U1-09)-2].

• Enable Slack Cable Detection by setting the C11-01 to 1.

• Select output action when Slack Cable is detected by defining C11-02.

Parmtr

Code

C11-01

Display

Slack Cable 0/1

C11-02

0 Disabled

1 Enabled

Action at SLC

Function

(For Hoist Application)

Determines whether Slack

Cable Detection is enabled.


0

Access

Level

Adv

2 Adv

0 No Action

1 No Act/C3-04

2 Decel/C3-04

3 Decel/No Opr

4 Dec Stop/C3-04

5 Dec Stop/No Opr

Multi-function output that occurs at Slack Cable

Detection. For all Selections,

RAISE command is permitted.

Alarm Only

Next LOWER command is at

Lower Limit 1 speed (C3-04).

Decelerate to Lower Limit 1

Speed C3-04. Continued

LOWER commands allowed, but at C3-04.

Decelerate to Lower Limit 1

Speed C3-04. Continued

LOWER commands are not allowed.

Decel (by C3-05) to Lower

Limit 1 Speed C3-04.

Continued LOWER commands allowed, but at

C3-04.

Decel (by C3-06) to stop.

Continued LOWER commands are not allowed.


5-46

Parmtr

Code

C11-03

C11-04

Display

SLC Detect Torq

SLC Detect Spd 1

C11-05 SLC Delay Time 1

C11-06

C11-07

SLC Detect Spd 2

SLC Delay Time 2

Function Range

Percentage of Output Torque below which the enabled

Slack Cable Detection is activated—as long as the

Frequency output is between

C11-04 and C11-06, and the delay time is between C11-05 and C11-07.

0–100%

The minimum Frequency

Output that is required for the enabled Slack Cable

Detection to be activated. It corresponds to Slack Cable

Detection Delay Time 1 (C11-

05).

0–150Hz

The minimum delay time before the enabled Slack

Cable Detection can be activated. It corresponds to

Slack Cable Detection Speed

1. Prevents false outputs.

The maximum Frequency

Output below which the enabled Slack Cable

Detection can be activated. It corresponds to Slack Cable

Detection Delay Time 2 (C11-

07).

0.00–2.55sec.

0–150Hz

The maximum delay time before the enabled Slack

Cable Detection can be activated. It corresponds to

Slack Cable Detection Speed

2. Prevents false outputs.

0.00–2.55sec.

Initial Value

30

2

0.50

60

0.10

Access

Level

Adv

Adv

Adv

Adv

Adv


5-47

Tuning

• D1 Injection

• D2 Automatic Slip Compensation

• D4 ASR Tuning

• D5 Torque Control

• D6 Droop Control

• D8 Dwell Function

• D9 S-Curve Acceleration/Deceleration

• D10 Carrier Frequency

• D12 Factory Tuning

DC Injection

DC Injection can be used to stop a motor whose rotational direction is uncertain at start-up.

With ramp to stop enabled (B3-03=0), upon removal of the run command the IMPULSE•VG+ Series

2 drive controls motor deceleration according to the Decel Time setting, until output frequency reaches the DC Injection Braking Start Frequency (D1-01 setting). Then the IMPULSE•VG+ Series

2 drive output is turned off and DC injection current is applied to the motor. The effective DC injection time and current should be set to provide adequate stopping without excessive motor heating. The DC injection voltage is determined by the DC injection braking current and motor impedance.

Parmtr

Code

D1-01

D1-03

D1-04

D1-05

D1-06

D1-07

Display

DCInj Start Freq

DCInj@Start

DCInj Time@Stop

DC Injection P Gain

DC Injection Integral Time

DC Injection Limit

Function

DC Injection braking frequency start.

DC Injection braking time.

DC Injection braking time at stop.

Range

0.0–10 Hz

Initial Value

1.5

0.00–10.00 sec 0.00

0.00–10.00 sec 0.05

0.00–1.00

0–1000 msec

0.0–30%

0.05

100

15.0

Access

Level

Adv

Adv

Adv

Factory

Factory

Factory


5-48

Figure 5-32: DC Braking Sequence


5-49

Automatic Slip Compensation

Parmtr

Code

D2-01

Display

Slip Comp Gain

Function Range

Slip compensation multiplier.

0.0–2.5

Automatic Speed Regulator (ASR) Tuning

Parmtr

Code

D4-01

D4-02

Display

ASR P Gain 1

ASR 1 Time 1

Initial Value

1

Access

Level

Adv

Function Range Initial Value

ASR Proportional Gain 1.

1.00–300.00

ASR Integral Time 1.

0.00–10.000 sec.

30

0.500

Access

Level

Adv

Adv

Parameters D4-01 and D4-02 provide adjustments to enable the optimum performance during load disturbances. The proportional gain (D4-01) adjusts the amount of instantaneous droop as a function of loss, and provides dampening from load disturbances such as speed reference change, or a change in load. The integral time (D4-02) adjusts the response time of the IMPULSE•VG+ Series 2 to the load disturbances.

NOTE: Speed control response is increased by increasing the proportional gain setting and decreasing the integral time. However, instability or hunting may occur between the

IMPULSE•VG+ Series 2 and the load if D4-01 (ASR Proportional Gain) is set too high, or

D4-02 (ASR Integral Time) is set too low.

Figure 5-33: Automatic Speed Regulator (ASR) Tuning


5-50

Figure 5-34: Examples of D4-01 and D4-02 Adjustments


5-51

Parmtr

Code

D4-03

D4-04

D4-06

D4-07

D4-08

Display

ASR P Gain 2

Function

ASR Proportional Gain 2.

Range

1.00–300.0

Initial Value

20

Access

Level

Adv

ASR 1 Time 2

ASR Delay Time ASR Output Primary Delay

Time.

Adv

Mechanical backlash in an application can cause secondary current (I

2

) reference variations in the motor’s rotor. This condition can prevent the desired adjustment of ASR parameters. The output delay time constant is used to increase the stability of the system allowing a wider setting range of ASR parameters.

ASR Gain SW Freq 0.0–150.0 Hz 0.0

Adv

ASR 1 Limit

ASR Integral Time 2.

ASR Gain Switching

Frequency.

ASR Integral Limit.

0.000–10.000 sec

0.5

0.000–0.500 sec 0.004

0–400% 400

Adv

Adv

Parameter D4-03 is used as an additional proportional gain adjustment, and parameter D4-04 determines the response time for Proportional Gain 2 (D4-03).

Figure 5-35: Proportional Gain

NOTE: When C5-07= “0,” proportional gain 1 (C5-01) and integral time 1 (C5-02) are selected.

Torque Control

Parmtr

Code

D5-01

D5-02

Display

Torque Control

Function

Determines whether Speed or

Torque Control is selected.


0

Access

Level

Adv

0

1

Speed Control

Torque Control

Speed Control enabled with torque limit

Torque control enabled with speed limit.

Speed/torque control selection can also be made by using a multi-function input select (H1-XX=39 speed- torque control changeover).

Torque Ref Filter Primary delay time for

Torque Reference Input.

0–1000msec 0 Adv


5-52

This function is used to avoid excessive changes in torque, which may be caused by abnormal resonance when the torque reference changes rapidly.

Torque Reference

(from Terminal 16)

1

1+sT d5-02

Torque

Reference

Parmtr

Code

D5-03

Display

Speed Limit Sel

D5-04

D5-05

D5-06

1 Analog Input

2 Program Setting

Speed Lmt Value

Speed Lmt Bias

Ref Hold Time

Function

Speed Limit Selection (See figure below)

Range

Speed Limit Value (% of

E1-04)

Speed Limit Bias (% of

E1-04)

Speed/Torque Switching

Timer

-120–120%

0–120%

0–120%

0

10

0

Initial Value

1

Access

Level

Adv

Adv

Adv

Adv

Figure 5-36: Torque Control Block Diagram

*1: When speed limit selection (D5-03) is set to “1”, the master frequency reference input from

terminal 13, 14 or 16 becomes the speed limit selection (D5-03) is set to “2”, the set value

of D5-04 becomes the speed limit.

*2: When terminal 14 or 16 function selection is set to torque compensation (H3-09= “14”),

terminal 14 or 16 set value can be used as the torque compensation value.


5-53

Speed/Torque Control Switching

Speed control or torque control can be selected “on the fly” by using the multi-function input speed/ torque control selection command (H1-XX = “39”).

Terminal

Number

8

13

16/14

Parameter

Number

H1-06

B3-01

D5-03

H3-05/H3-09

Setting

39

1

1

13

Descrption

Speed/torque control selection

Frequency reference selection (terminals 13, 14, or

16)

Speed limit selection (terminals 13, 14, or 16)

Torque reference/torque limit

Figure 5-37: Speed/Torque Control Selection Timing Diagram

1. When the speed/torque control selection contact is OFF, speed control is activated.

• Speed reference during speed control depends on the frequency reference selection (B3-01) setting. To use terminal 13, 14 or 16 as the master frequency reference, set B3-01 to “1.”

• Torque limit during speed control is the smaller of the absolute value of terminal 14 or 16 torque limit, or the values set in the torque limit parameters (C7-01 to C7-04) is used as the torque limit.

• When a stop command is given during speed control, speed control is maintained as the motor decelerates to stop and the smaller of the absolute value of the terminal 16 torque limit, or the values set in the torque limit parameters (C7-01 to C7-04) is used as the torque limit.

2. When the speed/torque control selection is ON, torque control is activated.

• Speed limit during torque control is the master frequency reference at terminal 13, 14 or 16 when speed limit selection (D5-03) is set to “1”, and is the speed limit value (D5-04) when


5-54

D5-03 = “2”, regardless of the frequency reference selection (B3-01) setting.

• During torque control, the terminal 14 or 16 analog input value becomes the torque reference.

3. By giving a stop command during torque control, operation changes to speed control automatically, and the motor decelerates to stop. The torque limit during deceleration to stop becomes the values set in the torque limit parameters (C7-01 to C7-04).

NOTE: The control mode actually changes after the speed/torque control selection command changes and the reference delay timer (D5-06) elapses. The speed reference/speed limit and the torque limit/torque reference are stored in the inverter until the time set to D5-06 elapses.

Droop Control

The Drooping function reduces the motor speed based on the load torque of the motor. The actual amount of motor speed reduction is based on the ratio of the amount of motor torque and maximum output frequency (E1-04).

The Droop Delay Time 06-02 sets the response time for the dropping function. Decreasing the

Droop Delay Time will cause the response to become quicker, however, instability may occur.

Parmtr

Code

D6-01

D6-02

Display Function

Droop Quantity Sets the motor speed reduction when torque output equals 100%

Droop Delay

Time

Sets the response time for the dropping function

Range

0.0 - 100.0

0.03 - 2.0 sec

Initial Value

0

0.05

Access

Level

Adv

Adv


5-55

Dwell Function

The Dwell Function is used to temporarily hold the output frequency at a set reference for a set time.

This function can be used when driving a motor with a heavy starting load. This pause in acceleration reduces traditionally high starting current.

Parmtr

Code

D8-01

Display

Dwell Ref @ Start

08-02

08-03

08-04

Dwell Time @ Start

Dwell Ref @ Stop

Dwell Time @ Stop

Function

Sets Dwell frequency reference at start.

Sets the time duration for the

Dwell function at start.

Sets dwell frequency

Reference at stop.

Sets the time duration for the

Dwell function at stop.

Range

0.0–150.0 Hz

0.0–10.0 sec

0.0–150.0 Hz

0.0–10.0 sec

0

0

Initial Value

0

Access

Level

Adv

0

Adv

Adv

Adv

Figure 5-38: Dwell Function


5-56

S-Curve Acceleration/Deceleration

A S-Curve pattern is used to reduce shock and provide smooth transitions during machine acceleration and deceleration. S-Curve characteristic time is the time from the output frequency to the set accel/decel time. See S-Curve Characteristic timing diagrams below and on the following page.

Parmtr

Code

D9-01

Display

S-Crv Acc @ Start

D9-02

D9-03

D9-04

S-Crv Acc @ End

S-Crv Dec @ Start

S-Crv Dec @ End

Function

Sets S-Curve time at Accel start

Range

0.00–2.50 sec

Sets S-Curve time at Accel end

0.00-2.50 sec

Sets S-Curve time Decel start 0.00–2.50 sec

Sets S-Curve time at Decel end

0.00–2.50 sec

Initial Value

1.50

Access

Level

Adv

1.50

1.50

0

Adv

Adv

Adv

Figure 5-39: S-Curve Characteristic Timing Diagram


5-57

The figure below shows FWD/REV run switching during deceleration to stop. The S-curve function will add time to the acceleration and decleration. Time to accelerate from the minimum frequency to the maximum frequency (total acceleration) = B5-01 + (D9-01 + D9-02)/2.

C A U T I O N


Figure 5-40: S-Curve Characteristics–FWD/REV Operation


5-58

Carrier Frequency

This function sets the inverter output transistor switching frequency (Carrier Frequency). Increasing the carrier frequency reduces motor noise. See Figure 5-41 below.

Parmtr

Code Display

D10-01 Carrier Frequency Max

0 0.4 kHz

1 1.0 kHz

2 1.5 kHz

3 2.0 kHz

4 2.5 kHz

5 5.0 kHz

6 10.0 kHz

Function

Carrier frequency upper limit.

Range

Initial

Value

4

Access

Level

Adv

Figure 5-41: Carrier Frequency Setting

NOTE: An OPE11 fault occurs if either of the following conditions is present:

1. D10-03>6 and D10-02>D10-01.

2. D10-01>5kHz and D10-02

≤5kHz.


5-59

Factory Tuning

During normal auto-tuning, the inverter is tuned while running at a carrier frequency of 2kHz. This parameter allows the user to specify the inverter’s carrier frequency during auto-tuning. Adjustment may be necessary if “OC” fault is displayed after completion of auto-tuning.

Parmtr

Code Display

D12-30 Carrier in tune

0 2kHz

1 Adjustable by D10-01

(Fc Upper Limit)

Function

Sets the carrier frequency during auto-tuning

Range

Initial

Value

0

Access

Level

–


5-60

Motor Parameters

• E1 V/f Pattern 1

• E2 Motor Set-up

• E3 Motor 2 Method

• E4 Motor 2 V/f Pattern

• E5 Motor 2 Set-up

Voltage/Frequency Pattern

Parmtr

Code

E1-01

Display

Input Voltage

Function

Sets input voltage

Range

155-255/

310-510

Initial

(1)

Value

230/460

Access

Level

User

Figure 5-42: E1-01 Input Voltage

• When using flux vector control mode, the V/f pattern voltage values will be adjusted by the

Auto-Tuning function.

• Factory setting is 230 (230V units), 460 (460V units) and 575 (575V units).


5-61

The setting E1-01 adjusts the overvoltage level, braking transistor turn on level and the stall prevention level during deceleration.

Overvoltage Trip Braking Transistor

Inverter

Voltage

E1-01

Setting Trip Reset On

230

460

460

575

150-255

≥

400

<400

>500V

400V

800V

720V

1040V

380V

760V

680V

990V

380V

760V

660V

990V

575 <500V 990V 940V 860V

Parameter E1-01 performs the above mentioned function in all three control modes.

Off

375V

750V

650V

970V

840V

Stall Level

380V

760V

670V

960V

830V

Parmtr

Code

E1-02

E1-03

E1-04

E1-05

(2)

E1-06

E1-09

E1-11

E1-12

E1-13

(2)

Display

Motor Selection

Function

Identifies motor as fancooled or blower-cooled

Range

Initial

(1)

Value

1

0 Stf Fan Cooled

1 Std Blower Cooled

V/f Selection

Max Frequency

Max Voltage

Base Frequency

Min Frequency

Mid Frequency B

Mid Voltage B

Select V/f Pattern F

Maximum Frequency “F” 40.0–400.0 Hz 60.0

Maximum Voltage “F” 0.0–510.0 V 460

Motor Base Frequency

Minimum Frequency

Midpoint Output

Frequency B

Midpoint Output

Voltage B

Motor Base Voltage

0.0–400.0 Hz

0.0–400.0 Hz

0.0–400.0 Hz

0.0–510.0 V

0.0–510.0 V

60

0.5

0.0

0.0

0.0

Base Voltage

(1)

The initial value displayed here is for 400V class drives..

(2)

For 230V class units, the value is half that of 400V class units.

Access

Level

User

-

User

User

-

User

Adv

Adv

User


5-62

Motor Set-up

E2 constants define motor parameters. Normally, the default settings for E2 constants are determined by KVA selection (O2-04). In flux vector control the E2 constants will be set automatically during auto-tuning. If the control method is V/F (A1-02=0), the motor rated current should be entered into E2-01.

If auto-tuning cannot be performed, some E2 constants can be calculated using the motor’s nameplate information.

Motor rated slip frequency (E2-02) can be calculated by using the following equation:

Motor terminal resistance E2-05 can be calculated by using the following equation:

Parmtr

Code

E2-01

E2-02

E2-03

E2-04

E2-05

E2-06

E2-07

E2-08

E2-09

Display

Motor Rated FLA

Motor Rated Slip

Function

Motor-rated current

Motor-rated slip frequency

No-Load Current

Number of Poles

Term Resistance

Leak Inductance

Saturation Comp 1

Motor no-load current

Number of poles in motor

Motor terminal resistance

Leakage Inductance

Saturation Comp 2

Core-Saturation Compensation

Coefficient 1

Core-Saturation Compensation

Coefficient 2

Mechanical Loss Motor mechanical loss in percentage

* Initial value is determined by O2-04 (kVA Selection)

Range

0.01–1500.0 A

0.00-20.00 Hz

0.0–1500.0 A

2-48

0.000–65.000

Ω

0.0–30.0%

0.00–0.50

0.00–0.75

0.0–10.0%

*

*

*

*

*

4

*

*

*

Initial

Value

Access

Level

User

User

User

Adv

Adv

Adv

Adv

Adv

Adv


5-63

Motor 2 Method

The Motor 2 method function allows one drive to control two separate motors which are coupled to separate motions. The output of the drive is switched from one motor to the other and a multifunction input (H1-XX=3b Motor 2 Select) informs the drive of which motor is being used.

W A R N I N G

Do not switch between motors when the drive’s output is on as it will damage the unit!

Parmtr

Code

E3-01

E3-02

Display

Control Method

0 V/f control

2 Open loop vector

Motion 2

0 Traverse

1 Standard Hoist

Function

Motor 2 control method

Motor 2 motion

Range

0–2

Initial

Value

2

Access

Level

Adv

0–2 1 Adv

Motor 2 Voltage/Frequency Pattern

Parmtr

Code

E4-01

Display

V/f 2 Max freq

E4-02

E4-03

E4-04

E4-05

E4-06

E4-07

V/f 2 Max voltage

V/f 2 Base Freq

V/f 2 Mid Freq

V/f 2 Mid Voltage

V/f 2 Min Freq

V/f 2 Min Voltage

Function

Maximum frequency for Motor

2

Range

40.0–400.0 Hz

Maximum voltage for Motor 2 0.0–255.0 V

50.0–400.0 Hz

50.0–400.0 Hz

Base frequency for Motor 2

Midpoint output frequency for

Motor 2

Midpoint output voltage for

Motor 2

Minimum output frequency for

Motor 2

Minimum output voltage for

Motor 2

0.0–255.0 V

0.0–400.0 Hz

0.0–255.0 V

12.6

0.5

2.3

Initial

Value

60.0

230.0

60.0

3.0

Access

Level

Adv

Adv

Adv

Factory

Factory

Factory

Factory


5-64

Motor 2 Set-up

Parmtr

Code

E5-01

E5-02

E5-03

E5-05

E5-06

Display

Motor2 Rated FLA

Motor2 Slip Freq

Function Range

Motor-rated current for Motor 2 0.0–150.0 A

Motor-rated slip frequency for

Motor 2

0.00–20.0 Hz

Motor2 No Load 1

Motor2 Term Ohms

Motor no-load current for Motor

2

0.0–150.0 A

Motor terminal resistance for

Motor 2

0.000–65.000

Ω

Motor2 Leak Leakage inductance for Motor 2 0.0–30.0%

* Based upon inverter models

*

*

Initial

Value

*

*

*

Access

Level

Adv

Adv

Adv

Adv

Adv


5-65

Option Parameters

• F1 Pulse Generator Option Set-up

• F2 Analog Input 14 Set-up

• F3 Digital Input Option Set-up

• F4 Analog Output Option Set-up

• F5 Digital Output 2 Set-up

• F6 Digital Output 8 Set-up

• F7 PG Output 36 Set-up

Encoder (PG) Option Set-up

Parmtr

Code

F1-01

F1-02

Display

PG Pulses/Rev

PG Fdbk Loss Sel

F1-03

0 Ramp to Stop

1 Coast to Stop

2 Fast-Stop*

3 Alarm Only

PG Overspeed Sel

F1-04

F1-05

F1-06

0 Ramp to Stop

1 Coast to Stop

2 Fast-Stop*

3 Alarm Only

PG Deviation Sel

0 Ramp to Stop

1 Coast to Stop

2 Fast-Stop*

3 Alarm Only

PG Rotation Sel

0 Fwd = C.C.W.

1 Fwd = C.W.

PG Output Ratio

Function

Sets encode Pulses/Rev

Selects stopping method or alarm output when PG line break is detected.

Decels to stop

Immediate stop

Decel by B5-08

Displayed on keypad only

Selects stopping method or alarm output when motor overspeed is detected.

Decels to stop

Immediate stop

Decel by B5-08


Selects stopping method when

PG deviation is detected.

Decels to stop5

Immediate stop

Decel by B5-08


Selects PG rotation

Range

0–60000 pulses/rev

1

1

0

Initial

Value

1024

1

Access

Level

Adv

Adv

Adv

Adv

Adv

PG division rate (pulse output) 1-132 1 Adv

NOTE:

*Fast-stop is selected, the stopping time is set by B5-08 (Fault stop time)


5-66

Parmtr

Code

F1-07

Display

PG Ramp PI/I Sel

F1-08

F1-09

F1-10

F1-11

F1-12

F1-13

F1-14

F1-15

0 Disabled

1 Enabled

PG Overspd Level

PG Overspd Time

PG Deviate Level

PG Deviate Time

SFS Deviate

PG # Gear Teeth1

PG# Gear Teeth2

PGO Detect Time

AI-14 Set-up

Parmtr

Code

F2-01

Display

AI-14 Input Sel

0 3ch Individual

1 3ch Additional

Function

Enable/Disable speed control

(ASR) integral operation during acceleration/deceleration (see D4 sections)

Range

Function

Determines whether the 3channel input selection is individual or additional.

Range

Initial

Value

0

Access

Level

Adv

Motor overspeed detection level.

0–120%

Motor overspeed detection level.

0–2.0 sec

Excessive speed deviation level.

0–50%

Excessive speed deviation time.

0–10.0 sec

Soft starter deviation level 0-400 Hz

Number of gear teeth—Option 1.

0–1000

Number of gear teeth—Option 2.

0–1000

Open encoder circuit 0-10.0

115

0.0

10

0.5

120.0

0

0

2.0

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Adv

Initial

Value

0

Access

Level

Adv

Sets CH1 to CH3 input functions when AI-14B option is connected

Setting

0

1

Function

3-channel individual input

(factory default)

3-channel additonal input

CH1 (TC1 to TC4 CH2 (TC2 to TC4) CH3 (TC3 to TC4)

Substitute for terminals

13 & 17

Substitute for terminals

14 & 17

Substitute for terminals 16 & 17

Sum of CH1 to CH3 input values is used as the frequency reference value

When the 3CH individual input is used, parameter B3-01 is automatically set to “1” (frequency reference from control circuit terminal). The option/inverter reference selection, which is selected by a multi-function contact input (H1-XX= “IE”), is disabled when using the AI-14B option.


5-67

Digital Input Option Set-up

Parmtr

Code

F3-01

Display

DI Option Setup

0 BCD 1%

1 BCD 0.1%

2 BCD 0.01%

3 BCD 1Hz

4 BCD 0.1Hz

5 BCD 0.01Hz

6 BCD (5DG) 0.01Hz

7 Binary

Function

Selects the setting mode of the reference input from the DI-08 and DI-164 options

BCD 1% unit

BCD 0.1% unit

BCD 0.01% unit

BCD 1Hz unit

Range

0–7

BCD 0.1Hz unit

BCD 0.01Hz unit

Binary

DI–00: 255/100%

DI–16H, 12 bit selection:

DI–16H, 16 bit selection:

4096/100%

3000/100%

Set value is displayed in decimal notation

Initial

Value

0

Access

Level

Adv


5-68

Analog Output Option Set-up

When the 3CH individual input is used, parameter B3-01 is automatically set to “1” (frequency reference from control circuit terminal). The option/inverter reference selection, which is selected by a multi-function contact input (H1-XX=”IF”), is disabled when using the AI-14B option.

Initial

Value

2

Access

Level

Adv

Parmtr

Code

F4-01

Display

AO Ch1 Select

F4-02

F4-03

F4-04

1 Frequency Ref

2 Output Freq

3 Output Current

5 Motor Speed

6 Output Voltage

7 DC Bus Voltage

8 Output kWatts

9 Torque Reference

15 Term 13 Level

16 Term 14 Level

17 Term 16 Level

18 Mot SEC Current

19 Mot EXC Current

20 SFS Output

21 ASR Input

22 ASR Output

23 Speed Deviation

24 PID Feedback

26 Voltage Ref (Vq)

27 Voltage Ref (Vd)

29 Load Weight

31 Not used

32 ACR (q) Output

33 ACR (d) Output

35 Friction Torq

AO Ch1 Gain

AO Ch2 Select

AO Ch2 Gain

Function

Analog output option Channel 1 selection

Range

1–35

Analog output Channel 1 multiplier

Analog output option Channel 2 selection (Same as F4-01)

0–2.50

1–35

Analog output Channel 2 multiplier

0–2.50

1.00

3

0.50

Adv

Adv

Adv


5-69

DO-02 Digital Output Set-up

Parmtr

Code

F5-01

Display

DO-02 Ch1 Select

F5-02 DO-02 Ch2 Select

Function

Determines the DO-02 digital output Channel 1 selection

(Same as H2-01)

Determines the DO-02 digital output Channel 2 selection

(Same as H2-01)

Range

0–FF

0–FF

Initial

Value

0

Access

Level

Adv

1 Adv


5-70

DO-08 Digital Output Set-up

Parmtr

Code

F6-01

Display

DO-08 Selection

0 8ch Individual

1 Binary Output

2 Srl Com Output

Function

Selects Multi-Function Output

Selections for the DO-08 option.

Range

Initial

Value

0

Access

Level

Adv

Selects the multi-function output selections for the DO-08 option.

Setting Terminal No.

Description

0

8-Channel individual

(factory Default)

TD5/TD11

TD6/TD11

TD7/TD11

TD8/TD11

TD9/TD11

TD10/TD11

TD1/TD2

Overcurrent (SC, OC, GF)

Overvoltage (OV)

Inverter overload (OL2)

Fuse blown (FU)

Not used

Inverter overheat (OH)

During zero-speed detection

During speed agree

1 binary output

TD3/TD4

TD5/TD11

TD6/TD11

TD7/TD11

TD8/TD11

TD9/TD11

TD10/TD11

TD1/TD2

Binary output*

During zero-speed detection

During speed agree

During run

TD3/TD4 Minor fault

* When F6-01 is set to binary output (setting = “1”), use the table on the following page to read the DO-08 output.


5-71

TD8/TD11

(bit 3)

1

1

1

1

1

1

1

0

1

0

0

0

0

0

0

0

TD7/TD11

(bit 2)

1

1

0

1

1

0

0

1

0

1

1

0

1

0

0

0

TD6/TD11

(bit 1)

0

1

1

0

1

0

1

1

0

0

1

1

0

0

0

1

TD5/TD11

(bit 0)

1

0

1

0

1

1

0

1

0

1

0

1

0

0

1

0

Description

No Fault

Overcurrent (SC, OC, GF)

Overvoltage (OV)

Inverter overload (OL2)

Inverter overheat (OH)

Overspeed (OS)

Fuse blown (FU)

Not used

External fault (EF3~EF8)

Controller fault

Motor overload (OL1)

Not used

Power loss (UV1, UV2, UV3)

Excessive speed deviation (DEV)

PG disconnection (PGO)

Not used

PO-36F Set-up

Parmtr

Code

F7-01

Display

PO-36F Selection

0 1 X Output Freq

1 6 X Output Freq

2 10 X Output Freq



Function

Sets the number of pulse signals to be output from the PO-36F option

Range

Initial

Value

1

Access

Level

Adv


5-72

Terminal Parameters

• H1 Digital Inputs

• H2 Digital Outputs

• H3 Analog Inputs

• H4 Analog Outputs

• H5 Serial Communication Set-up

Digital Inputs

The IMPULSE•VG+ Series 2 has six multi-function contact inputs for the set-up of numerous functions. The following table lists the function selections for the multi-function contact inputs

(terminals 3 to 8) and indicates the control modes during which each function can be enabled. An

OPEO3 error will occur if a function is programmed in more than one terminal at the same time.

.

Parmtr

Code

H1-01

H1-02

H1-03

H1-04

H1-05

H1-06

Display

Terminal 3 Sel

(parameter)

Terminal 4 Sel

(parameter)

Terminal 5 Sel

(parameter)

Terminal 6 Sel

(parameter)

Terminal 7 Sel

(parameter

Terminal 8 Sel

(parameter)

0 Multi-Step Ref 2




4 Speed Hold 2

5 Accel Command

Function

Selects the multi-function inputs.

Same as H1-01

Same as H1-01

Same as H1-01

Same as H1-01

Same as H1-01

Ref Page

Number Range

Initial

Value

0

Multi-Step Speed 2.




Hold function (2nd step of

Three-Step Infinitely

Variable).

Acceleration function (2nd step of Two-Step Infinitely

Variable or 3rd step of Three-

Step Infinitely Variable).

5-3

5-3

5-3

5-3

4-10

4-10

0–45 1

0–45 7

0–45 9

0–45 24

0–45 E

Access

Level

Adv

Adv

Adv

Adv

Adv

Adv


5-73

6 Upper Lmt 1 N/O

7 Upper Lmt 2 N/O

8 Lower Lmt 1 N/O

9 Lower Lmt 2 N/O

A Upper Lmt 2 N/C

B Upper Lmt 2 N/C

C Lower Lmt 1 N/C

D Lower Limit 2 N/C

E M-Speed Gain 1

F Not used

10 M-Speed Gain 2

13 Ultra/Swift Lift

14 Torque Lmt Acc/Dec

15 Alt T-Lim Gain

16 Forward Jog

17 Reverse Jog

18 Forward Inch

19 Reverse Inch

1A Inch Repeat

1B Multi-Acc/Dec 1

1C Reference SW

1D Term 13/16 Switch

1E Option/Inv Sel

1F Program Lockout

24 External Fault

30 Term 13/14 Switch

31 Fault Reset N/O

32 Fault Reset N/C

34 Trim Ctl Increase

35 Trim Ctl Decrease

Upper Limit–SLOW DOWN;

Normally Open

5-24

Upper Limit–STOP; Normally

Open

5-24

Lower Limit–SLOW DOWN;

Normally Open

5-24

Lower Limit–STOP; Normally

Open

5-24

Upper Limit–SLOW DOWN;

Normally Closed

5-24

Upper Limit–STOP; Normally

Closed

5-24

Lower Limit–SLOW DOWN;

Normally Closed

5-24

Lower Limit–STOP; Normally

Closed

5-24


Multiplier 1

5-23 n/a

5-23

No function


Multliplier 2

Ultra-Lift enable


Deceleration


Multiplier

5-29

5-17

5-31

5-3

Jog Control FORWARD command

Jog Control REVERSE command

Inch Control

Inch Control

Inch Control

Acceleration and

Deceleration Changeover

Time

Analog/Digital Reference

Changeover. B1-10=1.

Open=Analog

Closed=Digital

5-3 n/a n/a n/a

5-15

5-13

Terminal 13/16 Switch

Option/Inverter Speed

Reference Changeover

(Option Speed Reference at closed)

Program Lockout

5-81 n/a n/a

See “External Fault response selection”

5-80

Terminal 13/14 Switch

5-81

Frault Reset; Normally Open

n/a

Fault Reset; Normally Closed n/a

Trim Control Increase

5-13

Trim Control Decrease

5-13


5-74

36 Brake Ans Back

37 Ext BaseBlk N/O

38 Ext BaseBlk N/C

3D Motor Select

41 DCInj Activate

43 Alt S-Ref UpLmt

45 Serial/Inv Swtch

Brake Answer-Back

Immediate Stop at STOP

Command; Normally Open

Immediate Stop at STOP

Command; Normally Closed

Motor 2 enabled

5-33 n/a n/a

5-64

DC Injection Brake

Alternate Upper Limit

Frequency Reference

n/a

5-4

Serial/Inverter Run and Speed

Reference Changeover

n/a


5-75

Digital Outputs

The IMPULSE•VG+ Series 2 has three multi-function control outputs for indicating various conditions. The following table lists the function selections for the multi-function contact output

(terminals 9, 25, and 26), and indicates the control modes during which each function can be enabled. Note that Terminals 25 and 26 are Terminals 1 and 2 respectively on G5OUT option card.

3

Parmtr

Code

H2-01

Display

Terminal 9 Sel

H2-02

H2-03

Terminal 25 Sel

Terminal 26 Sel

0 Brake Output

1 Zero Speed

2 Fref/Fout Agree 1

3 Fref/Set Agree 1

4 Freq Detect 1

5 Freq Detect 2

6 Inverter Ready

7 DC Bus Undervolt

8 BaseBlk 1

9 Option Reference

A Remote Operation

B Trq Det 1 N.O.

C Loss of Ref

D DB Overheat

E Fault

F Not Used

10 Minor Fault

Function

Assigns one of the following

48 multi-function digital output parameters to

Terminal 9, 25, or 26.

Terminal 1 on the G5OUT

Option Card

Terminal 2 on the G5OUT

Option Card

Closed when voltage or frequency is output

Closed when below B2-02 or

D1-01

Output when Frequency

Reference and Frequency

Output agree

Output when Ouptut

Frequency Reference equals

L4-01.

Closed when output frequency is < L4-01.

Closed when output frequency is > L4-01.

Closed when an inverter is not in a fault state

Closed when DC Bus voltage drops belowUV trip point.

Closed when the inverter is not outputting voltage.

Closed when the frequency reference is input from the digital operator.

Reference

Page

Number Range

---

---

--n/a

5-48

5-87

5-87

5-87

5-87 n/a n/a n/a

5-97

0–40

0–40

0–40

Closed when the RUN command is input from the digital operator.

5-97

Output when torque > L6-02

5-89

Closed when inverter has detected a loss of frequency reference

5-88

Closed when inverter displays “RH” or “RR” fault.

n/a

Closed during a major fault.

6-3

No function

Closed during minor fault or alarm.

6-3

Initial

Value

0

0

7F

Access

Level

Adv

Adv

Adv


5-76

Parmtr

Code Display

11 Reset Cmd Active

13 Fref/Fout Agree 2

14 Fref/Set Agree 2

15 Freq Detect 3

16 Freq Detect 4

17 Trq Det 1 N.C.

18 Trq Det 2 N.O.

19 Trq Det 2 N.C.

1A Forward Dir

1B Reverse Dir

1C Speed Increasing

1D BaseBlk 2 (N.C.)

1E Motor A/B Change

20 Auto-Rst Enabled

21 Overload (OL1)

22 OH Prealarm

30 Current Trq LIM

34 During RUN 2

35 Load Check Fault

36 Slack Cable Det

37 Upper Lmt input

38 Lower Lmt input

39 Up/Low Lmt input

3B During RUN 1

40 Fault Annunciate

Function

Closed when a reset command is present on the terminals

Reference

Page

Number Range

n/a

Closed when output frequency = frequency reference

Closed when output frequency = L4-03

Closed when output frequency is

≤

L4-03

Closed when output frequency

≥

L4-03

Open when torque > L6-02

5-87

5-87

5-88

5-88

5-89

Closed when torque > L6-05

5-89

Open when torque > L6-05

5-89

Closed at FWD/UP command n/a

Closed at REV/DOWN command

n/a n/a

Closed when speed is increasing

Open when inverter is not outputting voltage.

n/a

Closed when motor changeover is input to terminals

n/a

Auto-Reset Enabled

OL1 Overload fault code

Closed when “OH” is displayed on keypad

5-93 n/a n/a

Current Torque Limit

During Run 2 - ON:

Frequency output, OFF: Base block, DC injection braking, initial excitation

Load Check fault output

n/a n/a

5-27

Slack Cable Detection output

5-46

Closed when Upper Limit–

SLOW DOWN or Upper

Limit STOP is input

5-24

5-24

Closed when Lower Limit–

SLOW DOWN or Lower


Closed when Upper Limit–

SLOW DOWN or Upper

Limit STOP or Lower Limit–

SLOW DOWN or Lower


5-24

Output for RUN 1

Closed on specified faults.

n/a

5-78

Initial

Value

Access

Level


5-77

Digital Outputs—Fault Annunciate (H2-01~03=40)

Digital Outputs—Fault Annunciate

enables you to assign a set of six fault outputs to Terminals 1 and/ or Terminal 2 on the G5out cord. In addition, you can select whether each fault output is enabled.

NOTE: Terminal 9 can also be used for


; however, it is normally assigned to a brake output.

Before you start to program this feature, you may find it convenient to first photocopy the “Binaryto-Hexadecimal Conversion Worksheet” in this section. By being able to write in the worksheet’s boxes, you will find it easier to program the feature.

Programming


requires that you determine two 4-digit binary numbers and then convert these numbers to two 1-digit hexadecimal numbers. You enter the hexadecimal numbers when you program the drive.

To program


(assuming you are in

Programming Mode

):


5-78

9. From the following worksheet, select one of three fault output sets. (Each row is a set.)

Enter the one-zero combination that corresponds to the set (row) that you selected.

For example, if you selected Set 2, you would enter “1 0” in the first two columns from the left, which would represent the first two digits of the first binary number that you would convert later.

Table 5.1: Binary-to-Hexadecimal Conversion Worksheet

First digit from the left Second digit from the left

Set 1

Set 2

Set 3

1 or 0

1

1

0

1 or 0

1

0

1

1 or 0

BE7

OS

BE6

1 or 0

BE5

DEV

BE5

1 or 0

BE4

LL1

BE4

1 or 0

BE0

LL2

BE3

1 or 0

OL2

UL1

BE2

1 or 0

OL1

UL2

BE1

10. Determine which fault outputs should be enabled. To enable a fault output, enter 1 in the box above the fault output; otherwise, enter 0. Do this for each fault output in the set.

For example, if Set 2 is selected and LL1 and UL1=1, “1 0 0 0” and “1 0 1 0 “ would be the two 4-digit binary numbers.

11. Using the conversion table below, determine the 1-digit hexadecimal number for both

4-digit binary numbers.

Table 5.2

Binary Number

0111

1000

1001

1010

1011

1100

1101

1110

1111

0000

0001

0010

0011

0100

0101

0110

Hexadecimal

Number

D

E

B

C

F

9

A

7

8

5

6

3

4

0

1

2


5-79

Continuing with the example, “1 0 0 0” and “1 0 1 0 “ converts to “8A.”

External Fault Response Selection

It is sometimes desirable to have at least one external fault input to the drive. To properly program a multi-function input (H1-01 to H1-06) for this purpose an external fault response must be selected.

The table below shows the possible selections for an external fault response.

Table 5.3

External Fault Selection

N.O.

√

√

√

√

√

√

√

√

Input Level

Selection Dectection Method

During

Run N.C.

Always

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

Ramp to

Stop

√

√

√

√

External Fault Action

Coast to Stop

√

√

√

√

Fast-stop*

√

√

√

√

Alarm

Only

√

√

√

√

MFI Setting

Result

23

27

2B

2F

21

25

29

2D

22

26

2A

2E

20

24

28

2C

* Uses B5-08 timer

NOTE: (1) N.O. = normally open contact; N.C. = normally closed contact

(2) Setting 24 is the factory default


5-80

Analog Inputs

The IMPULSE•VG+ Series 2 has three analog inputs (two multi-function and one reference) for the external input of numerous references and limits.

Parmtr

Code

H3-01

H3-02

H3-03

H3-04

H3-05

Display

Term 13 Signal

0 OVDC to 10VDC

1 -10VDC to +10VDC

Terminal 13 Gain

Terminal 13 Bias

Term 16 Signal

0 0VDC to 10VDC

1 -10VDC to +10VDC

Terminal 16 Sel

H3-06

H3-07

H3-08

0 Aux Reference

1 Frequency Gain

2 Frequency Bias

4

5

6

7 Overtorque Level

8 Stall Prev Level

9 Ref Lower Limit

A Jump Frequency

B

Voltage Bias

Acc/Dec Change

DC Brake Current

PID Feedback

16 Term 16 SW Ref

1F Not Used

Terminal 16 Gain

Terminal 16 Bias

Term 14 Signal

0 0 to +10VDC

1 -10 to +10VDC

2 4 to 20mA

Function

Voltage for Terminal 13 analog input signal

Range

0-1

Initial

Value

0

Gain multiplier for Terminal 13 analog input signal

Bias multiplier for Terminal 13 analog input signal

Voltage for Terminal 13 analog input signal

0.0-1000.0%

6-1

100

-100.0–100.0% 0

0

Assigns one of the following function analog input parameters to Terminal 16

Auxiliary Reference

Frequency Gain

Frequency Reference Bias

Voltage Bias

Acceleration/Deceleration

Changeover

DC injection braking current

Overtorque Detection Level

0

Speed Reference Lower Limit

Jump Frequency

Proportional, Integral, and

Derivative (PID) Control

Feedback

Switching Level Reference for

Terminal 16

Do not use

Gain multiplier for Terminal 16 analog input signal

Bias multiplier for Terminal 16 analog input signal

Terminal 14 Signal Level

Selection

0000.0–

1000.0%

100.0

-100.0–100.0% 0.0

2

Access

Level

Adv

Adv

Adv

Adv

Adv


5-81

Parmtr

Code

H3-09

Display

Terminal 14 Sel

H3-10

H3-11

H3-12

1 Frequency Gain

2 Frequency Bias

4 Voltage Bias

5 Acc/Dec Change

6 DC Brake Current

7 Overtorque Level

8 Stall Prev Level

9 Ref Lower Limit

A Jump Frequency

B PID Feedback

1F Not Used

Terminal 14 Gain

Terminal 14 Bias

Filter Avg Time

Function

Assigns one of the following function analog input parameters to Terminal 14.

Range

Filter average time

0000.0–

1000.0%

-100.0–100.0%

0.00–2.00sec

Initial

Value

1F

100.0

0.0

0.00

Access

Level

Adv

Adv

Adv

Adv

Analog Outputs

The IMPULSE•VG+ Series 2 has two analog outputs for the external monitoring of drive conditions.

Parmtr

Code

H4-01

Display

Terminal 21 Sel

H4-02

H4-03

1 Frequency Ref

2 Output Freq

3 Output Current

6 Output Voltage

7 DC Bus Voltage

8 Output kWatts

15 Term 13 Level

16 Term 14 Level

17 Term 16 Level


20 SFS Output

24 PID Feedback

31 Not Used

Terminal 21 Gain

Terminal 21 Bias

Function

Assigns one of the following function analog output parameters to Terminal 21

Range


5-82

Initial

Value

2

Access

Level

Adv

0.00–2.50

-10.0–10.0

1.00

0.0

Adv

Adv

Parmtr

Code

H4-04

Display

Terminal 23 Sel

H4-05

H4-06

H4-07

Terminal 23 Gain

Terminal 23 Bias

AO Level Select

0 0 to +10VDC

1 -10 to +10VDC

Function

Sames as H4-01 except assigned to Terminal 23

Range

0.00–2.50

-10.0–10.0%

Initial

Value

3

1.00

0.0

0

Access

Level

Adv

Adv

Adv

Adv

Serial Communication Set-up

The IMPULSE•VG+ Series 2 uses communication port 6CN to communicate via MODBUS protocal.

Parmtr

Code

H5-01

Display

Serial Com Adr

H5-02

H5-03

Serial Baud Rate

0 1200 Baud

1 2400 Baud

2 4800 Baud

3 9600 Baud

Serial Com Sel

H5-04

0 No parity

1 Even parity

2 Odd parity

Serial Fault Set

H5-05

0 Ramp to Stop

1 Coast to Stop

2 Fast-Stop

3 Alarm Only

Serial Flt Dtct

0 Disabled

1 Enabled

Function

Serial communication address

Determines stopping method or fault at a serial fault occurrence

0–2

Determines stopping method or fault at a serial fault occurrence

Determines whether Serial

Fault Detection is enabled

Range

0–20

Initial

Value

1F

3

Access

Level

Adv

Adv

0

1

1

Adv

Adv

Adv

NOTE: After changing any H5 parameter, power to the inverter must be cycled.

NOTE: After initial communication, if the inverter is not communicated with for 2 seconds, a communication fault will occur (CE Memobus ERR).


5-83

Protection Parameters

• L1 Motor Overload

• L3 Stall Prevention

• L4 Ref Detection

• L6 Torque Detection

• L8 Hardware Protection

• L9 Automatic Reset

Motor Overload

The IMPULSE•VG+ Series 2 protects against motor overload with a UL-recognized, built-in electronic thermal overload function.

The electronic thermal overload function estimates motor temperature, based on inverter output current, frequency and time to protect the motor from overheating. When the thermal overload fault is activated, an “OL1” trip occurs, shutting OFF the inverter output and preventing excessive overheating in the motor. As long as the inverter is powered up, it continues to calculate the motor temperature.

When operating with one inverter connected to one motor, an external thermal relay is not needed.

When operating several motors with one inverter, install a thermal relay on each motor. In this case, set parameter L1-01 to “0.”

Parmtr

Code

L1-01

Display

MOL Fault Select

L1-02

0 Disabled

1 Coast to Stop

MOL Time Const

Function

Enable/disable motor overload detection.

Range

Initial

Value

1

(Immediate stop)

Time for OL1 fault when motor current is

≥

150% of the motor rated current.

0.1–5.0 min 1.0

Access

Level

Adv

Adv


5-84

Stall Prevention

This function automatically adjusts the output frequency, acceleration and/or deceleration rates in order to continue operation without tripping or “stalling” the inverter.

C A U T I O N


Parmtr

Code

L3-04

Display

StallP Decel Sel

0 Disabled

1 General Purpose

Function

Enable/Disable stall prevention during deceleration

See table below

See table below

Range

Initial

Value

0

Access

Level

Adv

If deceleration times are set too short for load conditions, the inverter automatically extends the deceleration time according to the main circuit DC bus voltage level. When using an optional braking resistor for the IMPULSE•VG+ Series 2, set parameter L3-04 to “0.” See the figure on next page.

Setting

0

(Disabled)

1

(General Purpose)

Description

Stall prevention during deceleration is disabled (factory default). An excessively short deceleration time will generate an overvoltage fault (OV), and the inverter will stop.

Stall prevention during deceleration is enabled.

The DC bus voltage level is monitored, and the deceleration rate is automatically extended to prevent an overvoltage condition. This deceleration rate may be longer than the set value (B5-02).


5-85

Figure 5-43: Stall Prevention During Deceleration


5-86

Reference Detection

The IMPULSE•VG+ Series 2 utilizes three different functions for detecting output frequency:

• When frequency agree is enabled using the multi-function contact outputs

(H2-XX=”2” or “13”), the contact closes whenever the output frequency “agrees” with the frequency reference, plus or minus the speed agree detection width.

• When desired frequency agree is enabled using the multi-function contact outputs

(H2-XX=”3” or “14”), the contact closes whenever the output frequency “agrees” with the speed agree detection level, plus or minus the speed agree detection width.

• When frequency detection is enabled using the multi-function contact outputs

(H2-XX=”4”, “5”, “15” or “16”), the contact closes whenever the output frequency is less than or more than the speed agree detection level, depending on which detection is selected.

Parmtr

Code

L4-01

Display

Spd Agree Level

Function

Speed Agree Level

Range

0.0–400.0 Hz

Initial

Value

0.0

Access

Level

Adv

Sets the detection level for the desired frequency agree 1 and frequency detection 1 and 2 functions.

The set detection level is effective during both FWD and REV operation.

Parmtr

Code

L4-02

Display

Spd Agree Width

Function

Speed Agree Width

Range

0.0–20.0 Hz

Initial

Value

2.0

Access

Level

Adv

Sets the detection width for frequency and desired frequency agree 1 and frequency detection 1 and

2 functions.

Parmtr

Code

L4-03

Display

Speed Agree Lvl ±

Function

Speed Agree Level ±

Range

-400.0–400.0

Hz

Initial

Value

0.0

Access

Level

Adv

Sets the detection level for the desired frequency agree 2 and frequency detection 3 and 4 functions.

The set detection level is effective during either FWD or REV operation, depending on the set detection level (positive value for FWD operation, negative value for REV operation).


5-87

Parmtr

Code

L4-04

Display

Speed Agree Width ±

Function

Speed Agree Width ±

Range

0.0–20.0 Hz

Initial

Value

2.0

Access

Level

Adv

Sets the dectection width for frequency and desired frequency agree 2 and frequency detection 3 and 4 functions.

Parmtr

Code

L4-05

Display

Ref Loss Sel

0 Stop

1 Run @ 80% Prev Ref

Function

Selects operation when the frequency reference when the control terminal is reduced by

90% within 400ms

Range

Initial

Value

0

Access

Level

Adv


5-88

Torque Detection

The overtorque detection circuit activates when the motor load causes the motor current to exceed the overtorque dectection level (L6-02). When an overtorque condition is detected, alarm signals can be sent to the multi-function output terminals 9, 25 and 26. To output an overtorque detection signal, select torque detection 1 at either of the multi-function contact outputs (H2-XX=”B” or

“17”). Refer to the H2 section Digital Output on page 5-76 for more details.

Parmtr

Code

L6-01

Display

Torque Det 1 Sel

0 Disable

1 At Speed Agree–Alarm

2 At Run–Alarm

3 At Speed Agree–Fault

4 At Run–Fault

Function

Activates overtorque detection and selects whether detection generates an alarm or a fault

(See Table 5.4 for details)

Range

Initial

Value

0

Access

Level

Adv

Table 5.4

Setting

0

1

2

3

4

Description

Overtorque detection is disabled (factory default).

Overtorque detection is enabled whenever at the speed agree level (when inverter is not accelerating or decelerating). Continue running after detection (OL3 alarm).

Overtorque detection is enabled always. Continue running after detection (OL3 alarm).

Overtorque detection is enabled whenever at the speed at the speed agree level.

Coast to a stop after detection (OL3 fault).

Overtorque detection is enabled always. Coast to a stop after detection (OL3 fault).

NOTE: To detect torque during acceleration or deceleration, set to “2” or “4.”

NOTE: To continue operation after overtorque detection, set to “1” or “2.” During detection, the digital operator displays an “OL3” alarm (blinking).

NOTE: To stop the inverter after an overtorque detection fault, set to “3” or “4”. During detection, the digital operator displays an “OL3” fault.


5-89

Parmtr

Code

L6-02

L6-03

Display

Torq Det 1 Lvl

Torq Det 1 Time

Function

Sets the overtorque detection as a percentage of inverter rated current, during V/f control, and motor rated torque during vector control.

Range

0–300%

The overtorque detection delay time inserts a delay, between the time motor current (or torque) exceeds the overtorque level

(L6-02) and when the overtorque detection function is enabled. The digital operator then displays “OL3”.

0.0–10.0 sec

Initial

Value

150%

0.1 sec

Access

Level

Adv

Adv

Overtorque detection 2 functions the same as overtorque detection 1 (L6-01), except that “0L4” is displayed on the digital operator instead. This function is used when two types of detection are output to the multi-function output terminals.

Figure 5-44: Overtorque Characteristics Timing Diagram


5-90

Parmtr code

L6-04

Display

Torq Det 2 Sel

0 Disable

1 At Speed

Agree–Alarm

2 At Run–Alarm

3 At Speed

Agree–Fault

4 At Run–Fault

Function

Activates overtorque detection, and selects whether detection generates an alarm or a fault.

(See Table 5.4 for details)

Range

Initial

Value

0

Access

Level

Adv

Setting

0

1

2

3

4

Description

Overtorque detection is disabled (factory default).

Overtorque detection is enabled whenever at the speed agree level (when inverter is not accelerating or decelerating). Continue running after detection (OL4 alarm).

Overtorque detection is enabled always. Continue running after detection (OL4 alarm).

Overtorque detection is enabled whenever at the speed agree level. Coast to a stop after detection (OL4 fault).

Overtorque detection is enabled always. Coast to a stop after detection (OL4 fault).

Overtorque detection 2 functions the same as overtorque detection 1 (L6-01), except that “OL4” is displayed on the digital operator instead. This function is used when two types of detection are output to the multi-function output terminals.

Parmtr

Code

L6-05

L6-06

Display

Torq Det 2 Lvl

Torq Det 2 Time

Function

Torque Detection 2 Level

Torque Detection 2 Time

Range

0–300%

0.0–10.0 sec

Initial

Value

150%

0.1 sec

Access

Level

Adv

Adv


5-91

Hardware Protection

The IMPULSE•VG+ Series 2 comes equipped with a number of built-in functions designed to protect the inverter and its components from damage.

Parmtr

Code

L8-02

Display

OH Pre-Alarm Lvl

L8-03 OH Pre-Alarm Sel

0 Ramp to Stop

1 Coast to Stop

2 Fast-Stop

3 Alarm Only

L8-10

L8-14

Ground Fault Detect

0 Disabled

1 Enabled

UV3 Detect

0 Disabled

1 Enabled

Function

Sets the heatsink temperature level for protection against overheat (OH).

Note: The inverter measures heatsink temperature by an negative temperature coefficient thermister.

Selects the stopping method when heatsink overheat is detected.

(Decel to stop using B5-02)

(Immediate stop)

(Decel to stop using B5-08)

(Operation continues and

“OH Heatsink Overtemp” is displayed on keypad)

Enables/disables ground fault detection

Range

50–110°C

3

1

Initial

Value

95

°

C

Access

Level

Adv

Adv

Adv

Enables/disables UV3 detection (MC-Answer Back)

0 Adv


5-92

Automatic Reset

When a fault occurs (listed in Table 1.1) during operation, the IMPULSE•VG+ Series 2 can be programmed for an auto restart operation to automatically reset the fault.

Parmtr

Code

L9-01

Display

Reset Select

L9-02

0 Disabled

1 Enabled

Reset Attempts

Function

Activates the fault auto-reset function.

Range

Initial

Value

1

Level

Access

Adv

L9-03

L9-04*

L9-05*

Reset Time

Reset Flt Sel 1

Reset Flt Sel 2

Sets the number of reset attempts.

Reset attempt counter is returned to zero if no faults occur within a ten minute period.

Sets the reset starting time

Reset Fault Select 1.

Reset Fault Select 2.

0–10

0.0–10.0 sec

0000–FFFF

0000–FFFF

3

0.5

0001

0080

Adv

Adv

Adv

Adv

* To program constant L9-04 and L9-05, refer to the example on the following page and follow steps 1 through 4:

1. Sign 1 to each fault code that you wish to enable the auto reset.

2. Sign 0 to each fault code that you wish to disable the auto reset.

3. Convert all Digits (1 to 4) from binary to hex.

4. Program L9-04 and L9-05 by entering the hex number obtained from step 3.

Figure 5-45


5-93

Example:

Enable auto-reset for UV1, OS and CE faults.

Table 5.5

HEX

Binary

L9-04

HEX

Binary

L9-05

0

D

E

V

0

Digit 4

2

0

P

G

O

1

O

S

0

0 0

0

R

H

0

0

L

F

0

– – – – –

0

P

F

Digit 3

0

0

O

L

2

0

0 0

– –

0

S

V

E

0

O

L

1

1

C

E

0

O

H

0

S

C

Digit 2

0

0

O

V

0

C

A

L

L

8

0

E

F

8

0

E

F

7

0

G

F

0

E

F

6

0

O

C

0

E

F

5

Digit 1

1

0

U

V

3

0 1

U

V

2

U

V

1

0

0 0

E

F

4

E

F

3

Table 5.6

L9-04

Digit 4

Digit 3

Digit 2

Digit 1

Binary

0010

0000

0000

0001

HEX

0

1

2

0

Table 5.7

Binary Number

0111

1000

1001

1010

1011

1100

1101

1110

1111

0000

0001

0010

0011

0100

0101

0110

Hexadecimal

Number

D

E

B

C

F

9

A

7

8

5

6

3

4

0

1

2


5-94

Operator Parameters

• O1 Monitor Selection

• O2 Keypad Key Selection

• O3 Clear History

Monitor Selection

The top level in the operation mode allows the viewing of four monitor variables. They are Fref,

Fout, Iout, and User-Selected monitor. This user-selected monitor can be selected from the following table. See Monitor Parameters table on page 5-101 for available monitors by control method.

Parmtr

Code

O1-01

Display

User Monitor Sel

4 Control Method

5 Motor Speed

6 Output Voltage

7 DC Bus Voltage

8 Output kWatts

9 Torque Reference

10 Input Term Sts

11 Output Term Sts

12 Int Ctl Sts 1

13 Elapsed Time

14 FLASH ID

15 Term 13 Level

16 Term 14 Level

17 Term 16 Level


19 Mot EXC Current

20 SFS Output

21 ASR Input

22 ASR Output

23 Speed Deviation

24 PID Feedback

25 DI-16 Reference

26 Voltage Ref (Vq)

27 Voltage Ref (Vd)

28 CPU ID

29 Load Weight

32 ACR(q) Output

Function

Assigns one of the following monitor parameter as userselected monitor.

Range

4N35

Initial

Value

6

Access

Level

Adv


5-95

Parmtr

Code

O1-02

Display

33 ACR(d) Output

34 OPE Detected

35 Friction Torque

Power-On Monitor

Function

O1-03

1 Frequency Ref

2 Output Freq

3 Output Current

4 User Monitor

Display Scaling

Range

Selects the monitor to be displayed on the digital operator immediately after the power supply is turned on.

(U1-01)

(U1-02)

(U1-03)

(01-01)

Units for parameters and monitor related to frequency reference and output frequency can be scaled as shown below.

0–39999

2

0

Initial

Value

Access

Level

Adv

Adv

Table 5.8

Setting (O1-03)

00000

00001

00002 to 00039

00040 to 39999

(user-selected units)

Description

Unit: 0.01Hz (factory default)

Unit: 0.01%

Unit rpm (0 to 3999) setting = number of motor poles

Digits: 5th 4th 3rd 2nd 1st

0 0 0 0 0

The first thru fourth digits determine the set value at 100% output frequency.

Decimal point position is set by the fifth digit as follows:

5th digit = 0: displayed as 0000

5th digit = 1: displayed as 000.0



Example 1

If 100% output frequency is equal to 200.0 units: Set O1-03=”12000”; 100% of this reference is displayed as 200.0 and 60% of this reference is displayed as

120.0.

Example 2

If 100% output frequency is equal to 65.00: Set O1-03=”26500”; 60% of this reference is displayed as 39.00.


5-96

Parmtr

Code

O1-04

O1-05

Display

Display Units

0) Hertz

1) RPM

Address Display

Function

Display units for motor speed

0 Parameter Number

1 MEMOBUS Address

Selects how the parameter addresses are displayed on the digital operator.

Range

Keypad Key Selection

Parmtr

Code

O2-01

Display

Mode/Service

Function

1. Pressing the mode key once will Enable/disable the digital operator MODE/

SERVICE key (see diagram below)

Range

Initial

Value

0

Access

Level

Adv

0 Adv

Initial

Value

0

Access

Level

Adv

0 Mode/Service

1 Remote Local

O2-02 Oper Stop Key

0 BB, Brake Set

1 Decel tim1 Stop

2 Decel tim2 Stop

3 Decel Fault Stop

2. Pressing the key again

Displays the “Call ESI

Service” 800-288-8178.

Local/remote key is enabled depressing the local/removed key switches operation command between the digital operator and the settings of

B3-01 and B3-02.

Selects the action when the digital stop key is pressed.

(Immediate stop)

(B5-02)

(B5-04)

(B5-08)

0 Adv


5-97

O2-03 User Defaults

0 No Change

1 Set Defaults

F) 2075

20 40P4

21 40P7

22 41P5

23 42P2

24 43P7

25 44P0

26 45P5

27 47P5

28 4011

29 4015

2A 4018

2B 4022

2C 4030

2D 4037

2E 4045

2F 4055

30 4075

31) 4090

32 4110

0 20P4

1 20P7

2 21P5

3 22P2

4 23P7

5 25P5

6 27P5

7 2011

8 2015

9 2018

A 2022

B 2030

C 2037

D 2045

E 2055

O2-04

2 Clear all

KVA Selection

2080-FVG+

Not used

2130-FVG+

2160-FVG+

Not used

2224-FVG+

2300-FVG+

4001-FVG+

4003-FVG+

4005-FVG+

Not used

4008-FVG+

4011-FVG+

4014-FVG+

4021-FVG+

4028-FVG+

Memorizes up to 50 modified parameters. User defaults can be restored by setting

A1 - 05= “1110”.

Clear user defaults

Determines the model number of the drive, which is based on the kVA rating. The following in this column are

Electromotive Systems model numbers.

00-FF

Not used.

2006-FVG+

2008-FVG+

2011-FVG+

2017-FVG+

2025-FVG+

2033-FVG+

2054-FVG+

2068-FVG+

4034-FVG+

4041-FVG+

4052-FVG+

4065-FVG+

4080-FVG+

4096-FVG+

4128-FVG+

4165-FVG+

Not Used

4224-FVG+


5-98

0 Adv

Adv

O2-05

O2-06

33) 4132

34 4160

35 4185

36 4220

37 4300

42 51P5

43 52P2

44 53P7

45 55P5

46 57P5

47 5011

48 5015

49 5018

4A 5022

4B 5030

4C 5037

4D 5045

4E 5055

4F 5075

50 5090

51 5110

52 5160

Up/Down Freq Ref

0

1

Disabled

Enabled

Oper Detection

Not Used

4302-FVG+

Not used

4450-FVG+

4605-FVG+

5003-FVG+

5004-FVG+

5006-FVG+

5009-FVG+

5012-FVG+

5017-FVG+

5022-FVG+

5027-FVG+

5032-FVG+

5041-FVG+

5052-FVG+

5062-FVG+

5077-FVG+

5099-FVG+

5130-FVG+

5172-FVG+

5200-FVG+

Selects whether the ENTER key is used when the frequency reference is set by the digital operator. The digital operator can simulate a motor operated potentiometer (M.O.P.) by setting this parameter.

ENTER Key Required

ENTER Key Not Required

0 Adv

Note: This feature cannot be used in conjuction with infinitely variable speed control.

If the digital operator is disconnected from the inverter. This parameter selects whether the inverter detects this condition. The operator is only detected when the inverter is being commanded locally.

1 Adv

O2-07

O2-08

0 Disabled

1 Enabled

Elapsed Time Set

Elapsed Time Run

0 Power-On Time

1 Running Time

Viewable by U1-13

Defines the operation time that accumulates in the timer.

0–65535 0

0

Adv

Adv


5-99

Clear History

Parmtr

Code

03-01

03-02

Display

Clear History 1

0 Not Clear

1 Clear

Clear History 2

0 Not Clear

1 AC Count Clr

2 OL/LC Count Clr

3 Both Count Clr

Function

Clears fault history

Clears count history

Number of run command is received (U3-09)

Number of OL or LC fault is detected (U3-10)

Both (U3-09 and U3-10)

Range

Initial

Value

0

Access

Level

Adv

0 Adv


5-100

Monitor Parameters

Parmtr

Code Display Function Units Access Level

U1-14

U1-15

U1-16

U1-17

U1-18

U1-19

U1-20

U1-21

Monitor

U1-01

U1-02

U1-03

U1-04

U1-05

U1-06

U1-07

U1-08

U1-09

U1-10

U1-11

U1-12

U1-13

U1-22

U1-23

U1-24

U1-25

U1-26

U1-27

U1-28

Frequency Ref

Output Frequency

Output Current

Control Method

Motor Speed

Output Voltage

Frequency Reference

Inverter Output Frequency

Inverter Output Current

Displays the value of A1-02

Motor Speed

Inverter Output Voltage

(Reference)

DC Bus Voltage

Output kWatts

Torque Reference

Input Term Sts

DC Bus Voltage (Meausred)

Inverter Output Power

(Calculated)

Torque Reference (Internal)

Input Terminal Status (See page

5-103 for a detailed description.)

V kW

% n/a

Output Term Sts

Int Ctl Sts 1

Elapsed Time

Flash ID

Terminal 13 Level

Terminal 14 Level

Terminal 16 Level

Mot SEC Current

Mot EXC Current

SFS Output

ASR Input

ASR Output

Speed Deviation

Output Terminal Status (See page 5-104 for a detailed description.) n/a

Operation Status (See page 5-105 for a detailed description.) n/a

Elapsed Time. See O2-07 and

O2-08.

hours

Flash ROM software ID number n/a

External Terminal 13 input level V

External Terminal 14 input level V/mA

External Terminal 16 input level

Motor secondary current (lq).

Motor excitation current (ld).

Primary freq. after the SFS

Monitors the input to the speed regulator.

100%=FMAX

Monitors the output from the speed regulator.

The motor’s secondary current corresponds to 100%.

Monitors the speed deviation within the speed regulator.

FMAX=100%

PID feedback signal level

See page 5-29.

PID Feedback

G5IN4 Monitor

Voltage Reference (Vq) Motor secodnary voltage reference

Voltage Reference (Vd) Motor excitation voltage reference

CPU ID CPU software ID number

V

A

A

Hz

%

%

%

%

Hex

V

V n/a n/a

Hz

V

Hz

Hz

A

Operation

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

Advance

Advance

Advance

Advance

Advance

Advance

Advance

Advance

Advance

Advance

Advance

Advance

Advance

Advance


5-101

Parmtr

Code Display

U1-29 Load Weight

U1-32

U1-33

U1-34

U1-35

ACR (q) Output

ACR (d) Output

OPE Detected

Friction Torq

Function

Monitors load weight when C10-

01 is enabled

Units Access Level

tons Advance

%

%

Advance

Advance const # Advance

% Advance

Fault Trace

U2-01

U2-02

U2-03

U2-04

Current Fault

Last Fault

Frequency Reference

Output Frequency

U2-11

U2-12

U2-13

U2-14

U2-05

U2-07

U2-08

U2-09

Output Current

Output Voltage

DC Bus Voltage

Output kWatts

Input Terminal Sts

Output Terminal Sts

Inverter Status

Elapsed Time

Displays current fault

Displays last fault detected

Freq ref when fault was detected Hz

Hz Output freq when fault was detected

Output current when fault was detected

A

V Output voltage when fault was detected

DC Bus voltage when fault was detected

Output power when fault was detected

Input terminal status when fault was detected

V kW n/a

Output terminal status when fault was detected n/a n/a Inverter status before fault was detected

Elapsed time when fault was detected hours

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

Fault History

U3-01

U3-02

U3-03

U3-04

U3-05

U3-06

Last Fault

Fault Message 2

Fault Message 3

Fault Message 4

Elapsed Time 1

Elapsed Time 2

U3-07

U3-08

U3-09

Elapsed Time 3

Elapsed Time 4

AC Operations

U3-10 OL/LC Count

Most recent fault

2nd most recent fault

3rd most recent fault

4th most recent fault

Elapsed time of most recent fault

Elapsed time of 2nd most recent fault

Elapsed time of 3rd most recent fault

Elapsed time of 4th most recent fault

Total number of RUN commands received since the AC counter was last cleared (03-02)

Total number of OL and LC faults detected since the OL/LC counter was last cleared (03-02)

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program

User Program


5-102

Figure 5-46: Input Terminal Status


5-103

Figure 5-47: Output Terminal Status


5-104

Figure 5-48: Inverter Status


5-105


c h a p t e r

6

Troubleshooting

IMPULSE•VG+ Series 2


Troubleshooting the Drive

In this troubleshooting section, “check,” means investigating whether an item is functioning and in

an acceptable physical condition, and then taking corrective action (adjusting, fixing, replacing,

etc.) as necessary. In the Corrective Action column, you may not have to perform all of the steps to correct the problem.

Maintenance and Inspection

This section describes basic maintenance and inspection procedures for the IMPULSE•VG+ Series

2.

Component

External terminals, connectors, mounting screws, etc.

Heatsink

Printed Circuit Board (PCB)

Cooling Fan

Power Components

Check

Loose screws or connectors

Corrective Action

Securely tighten.

Build-up of dust and dirt Blow with dry, compress air (57-86 psi).

Accumulation of conductive dust or oil

Blow with dry, compress air (57-86 psi). If dust and oil cannot be removed, replace the board.

Abnormal noise and vibration

Accumulation of dust or dirt

Clean or replace the fan.

Blow with dry, compress air (57-86 psi).

Alarm and Fault classes are described as follows:

• Major Fault: Brake is set, operation indicator lights flash, fault is displayed on keypad and fault contact output (terminals 18, 19 & 20) are activated. The reset key must be pressed, a multifunction input set for fault reset or power must be cycled in order to continue operation.

• Fault (minor): Brake is set, RUN Led flashes until run command is removed, fault is displayed on keypad, fault contact output (terminals 18, 19 & 20) are not activated. The reset key does not need to be pressed. The drive will attempt to run again at the next run command.

• Alarm (Warning): Operation continues, fault is displayed on the keypad, fault contact output

(terminals 18, 19 & 20) are not activated.


6-3

Motor Faults and Corrective Actions

Symptom

Analog frequency reference is not stable. (drifting)

No motor rotation.

Motor rotation is in the wrong direction.

Motor rotates, but at minimum speed only.

Motor RPM too high or too low


1. Stabilize the analog source.

2. Increase B2-02.

3. Increase B5-01, -02.

1. Verify that power is on (Charge LED).

2. Verify that the keypad display is not showing a fault.

3. Verify that the run command is input to the drive (U1-10).

4. Motor stalled due to excessive load.

1. Verify FWD/REV or UP/DN is correct at the interface card.

2. Match wiring to the phase to the phase order of the motor leads T1, T2, T3.

1. Check wiring of speed inputs.

2. Verify speed reference setting (A1-04).

3. Verify reference and run source settings are correct (B3-01, -

02).

4. Verify reference priority setting (B1-10).

1. Compare motor nameplate specifications with E1 parameter.

2. Check maximum frequency setting (E1-04).

3. Check minimum frequency setting (E1-09).

Drive Faults and Indicators

Fault Code

BB

Base Block

BE0

Brake Ans Lost

BE1

Rollback detect

Fault or Indicator Name/Description Corrective Action

External Base Block Indicator The flashing base block signal is the result of a multi-function input in the terminal strip. The base block indicates that the drive’s IGBTs have been disabled. The motor will begin coasting when the base block input is received. If a RUN command is still present when the BB signal is removed, the output voltage will be restored to the previous operating level and operation will continue at the previously commanded frequency.

1. Check constants H1-01 through H1-06 for proper programming.

2. Check terminal status.

Brake answer back signal is lost during run.

While running, the multi-function input brake answer back is lost.

Torque Proving Minor Fault. At START, pulse feedback, after brake release, is greater than C8-05 count. There is no excessive roll-back at start.

1. Check brake answer back circuit.

2. Check terminal status. (U1-10)

1. See BE1 timing diagram on page

5-36. Increase value of C8-03.

2. Check for motor shaft movement after brake release.

3. Increase the value of C8-05.

4. Check the encoder signal for noise.

5. Check encoder grounding.

6. Check encoder shielded cable.

7. Replace encoder.


6-4

Fault Code

BE2

No Current

BE3

Brake Release NG

BE4

Brake Answer 1

BE5

Brake Answer 2

BE6

Brake Stop Fault

BE7

Brake Welded

CALL

Serial Com Call

CE

Memobus Com Err

CPF00

Com-Err (OP&INV)


Current-Proving Minor Fault. At START for

Torque Proving Sequence only - Current (IFB) has not reached predetermined setting within predetermined time at START.

1. See Timing diagram NLB.UP on page

5-34.

2. If powerlimit switch is used, switch is closed.

3. Make sure motor has been auto-tuned properly

4. Increase the value of C8-01 and C8-

02.


Brake Release Minor Fault. For Brake Release-

Check Sequence only-Speed feedback is less than

C8-07 counts. After electric brake release command is output - Electric brake not released.

1. See NLB_BE3 on page 5-37.

2. Check programming of H2-01 & H2-

02.

3. Check electric brake.

4. Check brake contactor(s).

5. Check encoder and wiring.

6. Increase the value of C8-06 timer.

7. Decrease the value of C8-07 counts.

Brake Answer-Back Minor Fault Released. At

Start, Brake Answer-back is not input within predetermined time (C8-04) after electric brake release command is output–Electric brake not released.

1. See NLB_UP on page 5-34.

2. Check brake answer back circuit.


4. Check terminal status (U1-10).

Brake Answer-Back At Stop. At Stop, Brake

Answer-back signal is not removed within predetermined time (C8-11) after electric brake release command is removed–Electric brake not closed.

1. See NLB_UP on page 5-34.

2. Check brake answer back circuitries

3. Increase the value of C8-11 time.

Note: A1-02 must = 2 OLV

Brake Set Alarm. At stop, Brake proving Sequence only - Pulse feedback after brake command removed, is greater than C8-13 count - Excessive movement through brake, not closed, or worn brake.

1. See NLB_BE6 on page 5-38.

2. Check if brake is failed in the open position, is improperly adjusted, or has worn pads.

3. Increase the value of C8-11 timer.

4. Increase the vaule of C8-13 counts.

5. Check encoder signal for noise.

Ensure encoder shielded cable is in good condition.

6. Replace encoder.

Brake Answer-Back Major Fault. At Power Up,

Brake Answer-Back is on - Electric brake not closed.

Serial Communication SI-B Transmission Fault.

Control data is not received correctly after power supply is turned ON for 2 sec.

Communication Error. Serial communications disruption.

1. Check if brake is closed.

2. Check brake answer back circuitry.

1. Check serial device connections.

2. Ensure drive is properly programmed for serial communication.

1. Check serial connections (6 CN).

2. Check H5-01 through H5-05 for proper programming.

Control Circuit Fault 1— Keypad Transmission.

Because of external noise, excessive vibration or shock, or component failure (including RAM and

PROM), one or both of the following occurs:

• Transmission between the inverter and keypad cannot be established 5 sec after power-up.

• MPU peripheral element check fault (on-line).

1. Check the keypad connection.

2. Check the control circuit wiring.

3. Replace keyboard.

4. Replace Control board.


6-5

Fault Code

CPF01

Com-Err (OP&INV)

CPF02

BB Circuit Err

CPF03

EEPROM Err

CPF04

Internal

A/D Err

CPF05

External

A/D Err

CPF06

Option Error

CPF10

CPF20

Option A/D Error

CPF21

Option CPU Down

CPF22

Option

Type Err

CPF23

Option DPRAM Err


Control Circuit Fault 2—Keypad

Transmission. After initial power-up, communication between the inverter and keypad was interrupted for more than 2 seconds.

Base Block Circuit Fault. Base block circuit fault at power-up.

EEPROM Fault. Invalid data found in the

EEPROM.

1. Check keypad connection.

2. Cycle Power

3. Replace keypad


1. Cycle power

2. Ensure that the control board terminals are shielded from electrical noise.


1. Cycle power



Internal A/D Converter Fault. CPU internal analog-digital converter fault.

External A/D Converter Fault. CPU external analog-digital converter fault.

1. Cycle power



1. Cycle power



Option Card Fault. Optional card has disconnected or failed.

1. Power down.

2. Verify proper installation of all option cards.

Control Circuit Fault 10 — G5IN4. G5IN4 option card failure.

1. Power down.

2. Verify proper installation of G5IN4.

3. Replace G5IN4 card.

Control Circuit Fault 20 — AI-14. Analog-todigital converter fails or analog speed reference error.

1. Power down.

2. Verify proper installation of AI-14B.

3. Replace AI-14B card.

Control Circuit Fault 21 — CPU on Optional

Card. CPU on an installed optional card fails.

1. Power down.

2. Verify proper installation of Option card.

3. Replace card.

Control Circuit Fault 22 — Optional Card Code.

Optional card code is not compatible with the inverter

1. Power down.

2. Verify proper card.


4. Replace card.

Control Circuit Fault 23 — DP-RAM. DP-RAM on an installed optional card failed.

1. Power down.

2. Remove any inputs to card.


4. Replace card.


6-6

EF

(Blinks)

External Fault

EF3

External

Fault 3

EF4

External

Fault 4

EF5

External

Fault 5

EF6

External

Fault 6

EF7

External

Fault 7

EF8

External

Fault 8

ERR

EEPROM

R/W Err

FAN

Fan Fault

GF

Ground Fault

Fault Code

Dev

Speed Deviation

LCI

Load Check Err


Speed Deviation Fault. Occurs when the deviation of the speed reference and speed feedback exceeds the regulation level, F1-10 for the time F1-11.

1. Check the load.

2. Reduce Accel/Decel times.

3. Check the encoder wiring.

4. Check the encoder grounding.

5. Increase Encoder Excessive Speed

Deviation Level (F1-10).

Both FORWARD/UP and REVERSE/DOWN commands are input at same time for 500 msec or longer

External fault occurs in the Terminal 3 external control circuit.

1. Check control input circuitries.

2. Check the sequence of operation.


1. Check constant H1-01 for proper programming.

2. Check the condition of the input terminal #3 on G5IF card.















EEPROM Read/Write Fault. EEPROM internal data did not match when initializing the parameter.

Cooling fan fails while power is on.

1. Cycle Power.

2. User initialize (A1-05=1110).


1. Remove any debris from fan.

2. Check fan wiring.

3. Replace fan (contact Electromotive

Systems).

During operation, the inverter sums the currents of all three motor phases. Ideally, the sum should always equal zero. If the sum is greater than 50% of the inverter rated output current, a GF occurs.

1. Disconnect motor from drive and check it for shorts using a megger

2. Ensure that R/C Surge Suppressors are used across all brake contactor coils to prevent disturbance by electrical transients.

3. With Output Phase Loss disabled (B6-

03), verify drive operation with motor disconnected.

Load Check Fault. Load is greater than specified amount.

1. Reduce Load.

2. Check Load Check sequence set-up.

(C5-XX).


6-7

Fault Code

LF

Output Pha Loss

LL1

Lower Limit 1 Err

LL2

Lower Limit 2 Err

OC

Over Current

OH

(blinking)

Heatsnk Over temp

OH1

Heatsnk Max Temp

OH2

Heatsink MaxTemp

OL1

Motor Overloaded

OL2

INV Overloaded

OL3

Overtorque

Det 1

OL4

Overtorque

Det 2

OP

OP3

OPE01

kVA Selection


An open phase occurred at the inverter output.

1. Check for broken wires in output cable.

2. Check for open winding in the motor.

3. Check for loose terminals

4. With Output Phase Loss disabled, verify drive operation with motor disconnected.

Lower Limit 1—SLOW DOWN

Indicator. Lower Limit 1—SLOW DOWN is input

(switch status is changed).

1. May not require corrective action.

2. Check the Limit Switches position.

3. Check the Limit Switches condition.

Lower Limit 2—STOP Indicator. Lower Limit

2—STOP is input (switch status is changed).


2. Check the Limit Switches position.

3. Check the Limit Switches condition.

Output current exceeds 200% of inverter rated output current.

1. Check for a phase-to-phase short in the motor or wiring using a megger.

2. Extend the acceleration/deceleration time.

Overheat Pre-Alarm. Cooling fan is overheating.

The temperature of the inverters cooling fans exceeded the setting in L8-02.

Cooling fan overheated. The temperature of the cooling fan has exceeded the factory setting.

1. The inverter cooling fan has stopped.

2. Reduce the ambient temperature.

1. The inverter cooling fan has stopped.

2. Reduce the ambient temperature.

Overheat Fault. There are two situations that result in an overheat fault. The first occurs when the measured heat sink exceeded 105°C. The second is a result of a fault in the internal 24VDC cooling fan.

1. Ensure that the heat sink cooling fans are functioning.

2. Ensure that the heat sink is free from dirt and debris.

3. Ensure that the inverter’s ambient temperature is within specification.

4. Replace the 24VDC fan

5. Replace the heat sink thermistor(s)

Motor Overload Fault. Inverter output exceeded the motor overload level.

1. Ensure drive is programmed with proper motor full load Amp (E2-01).

2. Reduce the load.

Inverter Overload Fault. Inverter output exceeded the inverter overload level.

1. Reduce the load.

2. Extend the acceleration time.

Overtorque Detection Level 1 Fault. Defined by

L6-02. Alarm defined by L6-01.

1. Check for proper programming for

L6-XX constant.

Overtorque Detection Level 2 Fault. Defined by

L6-05. Alarm defined by L6-04.

1. .Check for proper programming for

L6-XX constant.

Keypad Digital Monitor Fault. Digital monitor unit in keypad fails, or the keypad is mounted when in the program mode or during operation by the operator

1. Remove power and remount keypad.

1. Replace optional card.

Optional Card Fault. Optional card is incompatible or has failed.

kVA Setting Fault. Inverter kVA setting range is incorrect.

1. Check 02-04 constant for proper kVA.


6-8

Fault Code

OPE02

Limit

OPE03

Terminal

OPE05

Sequence Select

OPE06

PG Opt Missing

OPE07

Analog Selection

OPR

Oper Disconnect

OS

Over Speed

OV

DC Bus Overvolt

OV

(blinks)

DC Bus Overvolt

PF

Input Pha Loss

PGO

PG Open


Setting Out of Range . Parameter setting is out of range.

Multi-Function Input Setting Fault. Set values other than “F” and “FF” are duplicated.


1. With the fault displayed on the keypad, press the DATA/ENTER key to reveal the “Out of Range” parameter via the U1-34 monitor.

2. Verify that E2-03 is < E2-01.

3. Verify E1-05 is within range.

4. Compare Modified constants with defaults.

5. Cycle Power.

1. Check the settings for H1-01 to H1-

06, verify that the same input is not used twice.

1. Check the function selection or plug in optional card.

Sequence Select Setting Fault. B3-01 and B3-02 and no option is plugged in.

Missing PG Card. A closed loop control method was selected, and the required PG feedback card is not installed.

1. Install the required option card.

2. Remove power and reseat the option card.

3. Check the A1-02, control method, program setting

Multi-Function Analog Output Setting Fault.

H3-05 and H3-09 multi-Function analog output settings are set to the same value.

Keypad Disconnected. The keypad is removed while the inverter is running, and the run command was initiated via the keypad RUN key.

Overspeed Fault. The motor has exceeded the programmed detection level and time. This is typically caused by a overshoot condition due to an over-responsive ASR loop. If the drive is programmed to flux vector “torque control” mode, and no load is present, an overspeed fault will typically occur.

Overvoltage Fault. The main circuit direct current voltage exceeded the overvoltage level. Detection level:

230V class—approx. 400V

460V class—approx. 800V

1. Check the function selections.

1. Secure the keypad.

2. Verify O2-06 setting.

1. Check the Automatic Speed Regulator settings, C5 sub group.

2. Check for rapid load changes

3. Verify proper encoder PPR setting,

F1-01.

Overvoltage Fault. Overvoltage occurs during stop. Main circuit DC voltage rises above the detection level while the drive output is off.

Detection level: 410V or more for 230V and 820V or more for 460V

1. Check the line voltage.

Input Phase Loss Fault. Inverter input power supply has open phase.


2. Remove power.

3. Retighten the input terminal screws.

Pulse Generator Signal Missing Fault. The inverter detected a loss of encoder feedback.

1. Extend the deceleration time.

2. Check for proper DBU operation.

3. Check the resistor.


1. Check for missing or broken encoder wiring.

2. Check for proper direction of encoder feedback.

3. Check for a physical obstruction to rotor rotation (brake).


6-9

Fault Code

PUF

DC Bus Fuse Open

RH

DynBrk Resistor

RR

DynBrk Transistr

SC

Short Circuit

SLC

Slack Cable Detection


DC Bus Fuse Open Fault. The DC fuse is open. 1. Check for damaged transistor.

2. Check load-side short circuit.

3. Check grounding.

Do not replace an open DC bus fuse until the cause of failure has been corrected; non-warranty, damage to the drive may result.

Braking Resistor Overheat Fault. The factory installed, 3% dynamic braking resistor has exceeded an allowable temperature. This does not apply to

ESI external braking resistors.

1. Check the L8-01 setting. Only select

“provided” when using the factory installed 3% resistor.

2. Ensure that the braking duty cycle is not greater than 3% of the operation time.

Braking Transistor Fault. Internal Braking transistor failed.

1. Verify that the external braking resistor is connected to the proper terminals.

2. Confirm that the proper resistor is installed.

3. Check for a short circuit across the braking resistor

Short Circuit Fault. The inverter has detected an output short circuit condition.

Slack Cable Fault. A hoist slack cable condition occured.

Zero-Servo Fault.

1. Disconnect the motor from the inverter

2. Check for a short circuit in the motor or wiring using a megger.


2. Check proper programming of Slack

Cable Detection (C11-XX).

1. Check Zero-Servo sequence set-up.

SVE

Zero Servo Fault

SVR

PG Quality

THM

UL1

Upper Limit 1 Err

UL2

Upper Limit 2 Err

UV

DC Bus Undervolt

UV1

DC Bus Undervolt

UV2

CTL PS Undervolt

Noisy Encoder Fault.

1. Check encoder and encoder wiring.

2. Increase B7-01.

Thermistor Fault. Thermistor is not connected, or thermistor connection is faulty

Upper Limit 1—SLOW DOWN

Indicator. Upper Limit 1—SLOW DOWN switch status is changed.

Reconnect or replace thermistor.


2. Check the limit switches location.

3. Check the limit switches condition.

Upper Limit 2—STOP Indicator Upper Limit

2—STOP switch status is changed.


2. Check the limit switches location.

3. Check the limit switches condition.

Undervoltage Fault. Undervoltage status occurs for more than 2 sec during STOP. Input voltage drops below 210V DC or less for 230V AC class and

420V DC or less for 460V AC class.

1. Check the power source wiring.

2. Replace any bad branch fuses.

3. Check collector system.

Undervoltage 1 Fault. Undervoltage status occurs for more than 2 sec during RUN command. Input voltage drops below 190V or less for 230V AC class and 380V DC or less for 460V AC class.

1. Check power supply wiring.

2. Correct the line voltage.


Undervoltage 2 Fault. The inverter detected a loss of the 24V logic power supply voltage. This fault is only detected in inverters rated 4128-AFG+ through

4605-AFG+ and 2130-AFG+ through 2300-AFG+.





6-10

Fault Code

UV3

MC Answerback


MC Fault. The pre-charge contactor opened during operation.




4. Wait 30-45 seconds before restarting drive after auto shut down.


6-11

Fault Display and Corrective Actions at Auto-tuning

The following are fault displays and corrective actions at auto-tuning. If any of the following faults are found, the digital operator displays that fault contents; the motor coasts to stop if it is under operation. Fault contact output or minor fault contact output does not operate.

Fault Display

Data Invalid

(Motor data fault)

Resistance

(Line-to-line resistance fault)

No-Load Current

Saturation–1

Saturation–2

Rated Slip

Accelerate

PG Direction

Motor Speed

Alarm: Overload

(Displayed after completion of turning)


Motor data fault. Invalid motor data.


1. Verify input data.

2. Verify motor/drive capacities.

3. Change the settings to conform to the following equation: Rated speed < 120 x Motor frequency/ number of poles

Terminal resistance fault. Tuning was not completed within the specified time.

No-Load Current fault. Tuning was not completed within the specified time.

Iron core saturation coefficient 1 fault. The core saturation coefficient was not completed within the specified time.

1. Incorrect rated current setting

2. Check for loose/broken or disconnected motor wire

Iron core saturation coefficient 2 fault. the core saturation coefficient was not completed within the specified time.

Rated Slip Fault. Rated slip setting was not completed within the specified time.

Acceleration fault. Motor does not accelerate in specified time.

Motor rotating direction fault.

1. Verify that the motor is de-coupled from load.

1. Verify the brake is released (manually).

2. Increase acceleration time (B5-01).


4. Verify that C7-01, -02 = 150%.

1. Change F1-05

2. Swap T1 and T2 motor leads.

3. Check the PG wiring.

4. Check the motor wiring.

Motor Speed Fault. Torque reference becomes excessive (100%) during tuning.

Excessive tuning load. Torque reference exceeded 20% at tuning

1. Verify that the brake is released (manually).

2. Increase acceleration time B5-01.



2. Turn the power off and rotate the motor shaft by hand. Replace motor if it does not turn smoothly


6-12

Troubleshooting CDBR Faults

Fault Status Possible Cause

Drive trips at overvoltage (OV)

Braking Unit Thermal Overload trips when not decelerating

• Insufficient braking unit capacity

• Insufficient resistor capacity

• Improper wiring

• Deceleration time too short

• Braking unit fault

• Improper braking unit power supply voltage selection setting

• Incoming (line) voltage too high

• Discharge transistor shorted

Braking Unit trips by heatsink overheat • Excessive load inertia

• Improper combination of braking unit and resistor

• Ambient temperature > 104 o

F


1. Verify CDBR capacity

2. Verify resistor capacity

3. Verify wiring is correct

4. Lengthen deceleration time

5. Replace the braking unit

1. Verify Jumper setting

2. Correct Line Voltage

3. Replace the braking unit

1. Reduce load

2. Verify proper braking unit/resistor

3. Install air conditioner


6-13

Power Section Check

WA R N I N G

Do NOT touch any circuit components while AC main power is on or immediately after the main AC power is disconnected from the unit. You must wait until the red “CHARGE” lamp is extinguished. It may take as long as 10 minutes for the charge on the main DC bus capacitors to drop to a safe level. Failure to adhere to this warning could result in serious injury.

Power Off Checks

To perform a power section check, remove the drives main and control wiring from the terminal strips. Obtain reading as specified in the table on the next page, and ensure that the reading falls within the normal reading range.


6-14

Test equipment - Analog Ohmmeter set R x 1 scale or digital multimeter set to the diode check.

Device

Input Rectifier

Bridge

*1

VOM (on RX1 Scale)

Positive Lead Negative Lead

L1 +

L2

L3

–

–

+

+

L1

L2

+

+

+

+

–

L1

L2

L3

L1

L2

L3

–

L3

–

–

–

Normal Reading

(Analog Meter)

7–100

Ω

Infinite

Ω

Normal Reading

(Digital Meter)

Approximately

0.5 V

OL Displayed

Bus

Capacitors

Observe gradually increasing resistance

Observe gradually increasing voltage to

OL

– Pre-charge

Resistor

– Across the Resistors 100

Ω

or less

Output

Transistors

*2

*3

–

–

T1

T2

T1

T2

T3

–

T3

+

T2

T3

–

–

+

+

+

T1

–

T1

7-100

Ω

Infinite

Ω

Approximately

0.5V

OL Displayed

+ T2

+ T3

Braking Diode

(2006–2033)

(4001–4034)

B2

B1

B2

B1

B2

–

10

Ω

Infinite

Ω

Infinite

Ω

– B2 Infinite

Ω

*1. “+” could be any one of three (+) terminals which are labeled as

⊕

1,

⊕

2, and

⊕

3.

0.5 V

OL Displayed

OL Displayed

OL Displayed

*2. If the bus fuse is blown you must install a jumper across the fuse terminals to get accurate resistance measurements.

*3. I f the pre-charge resistor is open, you will need infinite

Ω

between + and any output terminal unless you install a temporary jumper across the resistor.


6-15

Braking Circuit

Test Equipment - Analog Ohmmeter set to R X 1 scale or digital multimeter set to the diode check.

Step No.

3

4

1

2

Ohmmeter

Positive Lead

Connect to B2

Connect to B1

Connect to B2

–

Ohmmeter

Negative Lead

Connect to B1

Connect to B2

–

Connect to B2

Expected Reading

(Analog Meter)

10 Ohms

Infinite Ohms

Infinite Ohms

Infinite Ohms

Expected Reading

(Digital Meter)

0.5 Volts

0L displayed

0L displayed

0L displayed

Figure 6-1

A p p e n d i x

A

Servicing

IMPULSE•VG+ Series 2


Service

This chapter includes information pertaining to on-call service, drive identification, troubleshooting, and warranty. Before you install, troubleshoot, or service the drive, we highly recommend that you read this entire chapter. Doing this will help assure quick service response, minimize your on-site repair costs, and reduce crane downtime.

Your IMPULSE•VG+ Series 2 drive includes a two-year warranty from date of shipment. The warranty is described in detail later in this chapter.

On-Call Service

If you ever require our assistance, contact us at (800) 288-8178; our fax number is (800) 298-3508.

Technical support is available 24 hours a day, seven days a week, and 365 days a year. If necessary, we can arrange to have a Service Technician visit your site to evaluate the situation.

Identifying Your Drive

If you ever have to contact Electromotive Systems about your drive, first determine the model and serial numbers of your drive by looking at the nameplate shown below.

IMPULSE

ELECTROMOTIVE SYSTEMS, INC.

MILWAUKEE, WISCONSIN

SERIAL NO.:

MODEL NO.:

A.C. INPUT

VOLTS: PHASE: 3

AMPS: HZ: 50/60

A.C. OUTPUT

VOLTS: PHASE: 3

AMPS: HZ: 0-400

H.P.:

Figure 6.1

This nameplate is normally located on the side of the drive nearest to the keypad.

Service Policy For Small Drives, DBUs, and Other Electrical Components

This section explains Electromotive Systems’ service policy for the small drives (2006-FVG+ through 2224-FVG+ and 4001-FVG+ through 4165-FVG+), dynamic braking units (DBUs), and other electrical components.

Should your IMPULSE product fail during the warranty period, Electromotive Systems will repair or replace your unit within 72 hours (3 working days). In most cases, we can supply a replacement unit within 24 hours (1 working day). If the problem is not covered under warranty, you are responsible for the cost of the repairs and the shipping charges.

To return a failed unit (or part):

1. Request a Return Authorization (RA) from Electromotive Systems’ Service Department, as a condition for us to repair or replace the unit. Return the failed unit to Electromotive Systems via

pre-paid freight. When you call, please have the serial number of the drive available and be prepared to provide the information requested on the Return Authorization Information Sheet found on page A-5.

2. A purchase order or credit card is required to cover the cost of the replacement unit or repairs to a returned unit.


A-3

Electromotive Systems will inspect the failed unit and determine if the unit is covered under warranty.

• If the unit is covered under warranty, Electromotive Systems will credit the cost of the replacement unit and/or repairs and reimburse for all reasonable freight charges.

NOTE: Freight charges incurred from sources other than common ground carriers WILL

NOT be reimbursed unless pre-approved by Electromotive Systems.

• If the unit is not covered under warranty, Electromotive Systems will bill you for the cost of the replacement unit or the cost of repairs. Electromotive Systems will also bill you for a $125.00 inspection fee (this fee will be waived if repairs are made to the unit) and any freight charges incurred by Electromotive Systems.

Service Policy for Large Drives

This section explains Electromotive Systems’ service policy for the large drive (2300-FVG+ and

4224-FVG+ and larger).

Because of the size and weight of large units, it may not be practical to return the entire drive to

Electromotive Systems for repair. If a drive has failed, you must first contact us by telephone for assistance in diagnosis. If necessary, we may authorize the on-site replacement of specific components and the return of these failed parts for credit, replacement, or repair.

These components include; but not limited to:

• Control/logic card

• Main base drive card

• Subbase drive card

• Drive unit transistor cassette

• Fan unit

• Main input diode circuit

• Capacitors

• DC Bus Fuses

• Electromotive Systems interface and special option cards.

On-site troubleshooting and the replacement of failed components is to be performed only by technicians approved by Electromotive Systems.

Follow procedures outlined above for returning components.


A-4

Electromotive Systems Limited Warranty

Electromotive Systems, Inc., hereafter referred to as Company, guarantees all items manufactured by it against any defects of material and/or workmanship for a period of two years from the date of shipment. Company makes NO OTHER WARRANTY, EXPRESSED OR IMPLIED, AS TO THE

MERCHANTABILITY OR FITNESS OF THE ITEMS FOR THEIR INTENDED USE OR AS TO

THEIR PERFORMANCE. Any statement, description or specification in Company’s literature is for the sole purpose of identification of items sold by the Company and imparts no guarantee, warranty or undertaking by company of any kind. Components and accessories not manufactured by

Electromotive Systems are not included in this warranty and are warranted separately by their respective manufacturers.

Company’s sole liability shall be to repair at its factory, or replace any item returned to it within two years from date of shipment, which Company finds to contain defective material or workmanship.

All items to be repaired or replaced shall be shipped to Company (Note: return authorization by

Company is required) within said two year period, freight prepaid, as a condition to repair or replace defective material or workmanship. Company’s herein assumed responsibility does not cover defects resulting from improper installation, maintenance, or improper use. Any corrective maintenance performed by anyone other than the Company during the warranty period shall void the warranty. Company shall not be liable for damages of any kind from any cause whatsoever beyond the price of the defective Company supplied items involved. 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 the use of any Company supplied items or material.

Company neither assumes nor authorizes any other person to assume for Company any other liability in connection with the sale or use of items sold by Company.

Materials or items may not be returned for credit, without the prior written consent of the Company.

Any authorized return of materials or items shall be subject to a restocking charge equal to 25% of the net invoiced amount ($100 minimum charge for all control products) after Company determines that the material or item is in resalable condition. If upon receipt of the material or items returned, the Company determines that said material or items cannot be resold without alteration or service, the Company reserves the right to reject the returned materials or items and to send the same back to said purchaser at purchaser’s expense.

Any claim for errors in shipment or for material or time shortages must be received by Company within 30 days of shipment and must be accompanied by copies of the bill of lading and packing slip.


A-6

IMPULSE•VG+ Series 2 Parameter Listing

B3-05

B3-06

B3-07

B4-02

B5-01

B5-02

B5-03

B5-04

B1-09

B1-10

B2-01

B2-02

B2-03

B3-01

B3-02

B3-03

B5-05

B5-06

B5-07

B5-08

B5-09

B5-10

B5-11

B5-12

B5-13

B5-14

No.

A1-01

A1-02

A1-03

A1-04

A1-05

Parameter Name

Access Level

Control Method

Motion

Speed Ref

Init Parameters

A1-06

A1-07

Password 1

Select Password 1

A2-01 to A2-30 User Parameters

B1-01 Reference 1

B1-02

B1-03

B1-04

B1-05

Reference 2

Reference 3

Reference 4

Reference 5

Jog Reference

Ref Priority

Ref Upper Limit

Ref Lower Limit

Upper Limit Gain

Reference Source

Run Source

Stopping Method

Zero-Speed Operation

Control Input Scans

Local/Remote Run Select

Trim Control Level

Acceleration Time 1

Deceleration Time 1

Acceleration Time 2

Deceleration Time 2

Acceleration Time N Change

Deceleration Time N Change

Hoist 2 Stop Decel

Fault Stop Time

Accel/Decel Units

Accel/Decel Switch Freq

Switch Freq Compare

Forward Torque Limit Accel

Forward Torque Limit Decel

Reverse Torque Limit Accel

5-7

5-12

5-12

5-13

5-14

5-14

5-14

5-14

5-4

5-5

5-5

5-5

5-3

5-3

5-4

5-4

5-15

5-15

5-15

5-15

5-15

5-15

5-15

5-17

5-17

5-17

5-3

5-3

5-3

5-3

4-11

4-11

4-11

5-3

Ref

Page#

4-9

4-9

4-10

4-10

4-11

3.5

2.5

1.0

1.0

0

1

0

10

6.00

0

100.0

2.0

100

1

1

0 or 6

1.0

1.0

0.3

0.3

1

120.0

1

0.0

0.0

0.5

0

0

---

15.00

30.00

60.00

45.00

60.00

Factory

Default

2

6

0

3

0 or 2


A-7

C3-06

C3-07

C4-01

C4-02

C4-03

C5-01

C5-02

C5-03

C1-05

C2-01

C2-02

C3-01

C3-02

C3-03

C3-04

C3-05

B8-01

B8-02

B8-03

B8-04

C1-01

C1-02

C1-03

C1-04

No.

B5-15

B6-01

B6-02

B6-03

B6-04

B7-01

C5-04

C5-06

C5-07

C5-09

C5-11

C5-12

C5-13

C5-14

C6-01

C6-02

C6-03

C6-04

C6-05


A-8

Parameter Name

Reverse Torque Limit Decel

Phase Loss Input Select

Phase Loss Input Level

Phase Loss Output Select

Phase Loss Output Level

SVR Delay Timer

Jump Frequency 1

Jump Frequency 2

Jump Frequency 3

Jump Bandwith

Quick Stop Enable/Disable

Quick Stop Time

Reverse Plug Enable/Disable

Reverse Plug Decel Time

Reverse Plug Accel Time

Micro Speed Gain 1

Micro Speed Gain 2

Upper Limit 1 Speed

Upper Limit 1 Decel Time

Upper Limit 2 Decel Time

Lower Limit 1 Speed

Lower Limit 1 Decel Time

Lower Limit 2 Decell Time

Action @ LL2/UL2

Zero Servo Timer

Zero Servo Gain

Zero Servo Count

Load Check Enable/Disable

Load Check Alarm Action

Min Torque Reference

Look Speed 1

Vector Torque Reference

Look Speed 2

Look Speed 3

Current Ref for > Look Speed 3

Load Check Setting Time

Load Check Test Time

Load Check Fault Speed

Swift/Ultra Lift Enable/Disable

Swift Lift Forward Speed

Swift Lift Reverse Speed

Swift Lift Forward Torque

Swift Lift Reverse Torque

5-24

5-24

5-26

5-26

5-26

5-27

5-27

5-27

5-22

5-23

5-23

5-24

5-24

5-24

5-24

5-24

5-19

5-19

5-19

5-19

5-21

5-21

5-22

5-22

Ref

Page#

5-17

5-18

5-18

5-18

5-18

5-18

5-27

5-27

5-27

5-27

5-27

5-27

5-27

5-27

5-29

5-29

5-29

5-29

5-29

0.5

0

10

25/50

10

0

2

60%

1.0

0.5

6

1.0

1.0

1.00

1.00

6

0

0.5

0

1.0

0.0

0.0

0.0

1.0

7.5

1

5.0

70

Factory

Default

0.0

0

6

125

20

60

160

0.20

0.10

6

0

60

60

50

30

C8-16

C8-17

C9-01

C9-02

C10-01

C10-02

C10-03

C10-04

C8-07

C8-08

C8-09

C8-10

C8-11

C8-12

C8-13

C8-15

C7-04

C7-07

C8-01

C8-02

C8-03

C8-04

C8-05

C8-06

No.

C6-06

C6-07

C6-08

C7-01

C7-02

C7-03

C10-05

C10-06

C10-07

C11-01

C11-02

C11-03

C11-04

C11-05

C11-06

C11-07

D1-01

D1-03

D1-04

Parameter Name

Swift Lift Enabling Speed

Swift Lift Delay Time

SFS Acceleration Gain

Forward Torque Limit

Reverse Torque Limit

Forward Regen Torque Limit

Reverse Regen Torque Limit

Torque Limit Gain by MFI

Torque Compensation Time

Current Feedback OK Timer

Minimum Brake Release Torque

Roll Back/BE4 Timer

Roll Back Count

BE3/Alternate Rev Torque Time

BE3 Detect Count

Alternate Reverse Torque Limit

Zero Speed Level

Load Float Time

Brake Delay Time/BE5 Timer

BE6 Detect Time

0.7

0.0

BE6 Maximum Count 50

Load Float Extension Time by MFI 10

50

10

2

10

Initial Brake Release Torque

BE6 Up Speed

G5IN4 Enable/Disable

G5IN4 Setup

Load Weight Enable/Disable

Torque Output Primary Delay

Load Weight Display Hold

Load Weight Conversion

0

0

0

200

0

0

100

6.00

1.0

150

150

180

Factory

Default

60

2.0

180

1.25

5-31

5-31

1.50/2.50

5-33

1.50/2.50

5-33

10

0.50

400

0.50

5-33

5-33

5-33

5-33

Ref

Page#

5-29

5-29

5-29

5-31

5-31

5-31

5-33

5-33

5-40

5-40

5-43

5-43

5-43

5-43

5-33

5-33

5-33

5-33

5-33

5-33

5-33

5-33

Full Load Torque Output

No Load Torque Output

Line 2 Display

Slack Cable Enable/Disable

Action at Slack Cable

Slack Cable Detection Torque

Slack Cable Detect Speed 1

Slack Cable Delay Time 1

Slack Cable Detect Speed 2

Slack Cable Delay Time 2

DC Injection Start Frequency

DC Injection Time @ Start

DC Injection Time @ Stop

60

0.10

1.5

0.00

0.05

0

0

100.0

0.0

2

30

2

0.50

5-43

5-43

5-43

5-46

5-46

5-47

5-47

5-47

5-47

5-47

5-48

5-48

5-48


A-9

D8-04

D9-01

D9-02

D9-03

D9-04

D10-01

D12-30

E1-01

D5-04

D5-05

D5-06

D6-01

D6-02

D8-01

D8-02

D8-03

D4-03

D4-04

D4-06

D4-07

D4-08

D5-01

D5-02

D5-03

No.

D1-05

D1-06

D1-07

D2-01

D4-01

D4-02

E1-02

E1-03

E1-04

E1-05

E1-06

E1-09

E1-11

E1-12

E1-13

E2-01

E2-02

E2-03

E2-04


A-10

Parameter Name

DC Injection P Gain

DC Injection Integral Time

DC Injection

Slip Compensation Gain

ASR P Gain 1

ASR I Time 1

ASR P Gain 2

ASR I Time 2

ASR Delay Time

ASR Gain Switch Frequency

ASR I Limit

Torque Control Select

Torque Reference Filter

Speed Limit Select

Speed Limit Value

Speed Limit Bias

Reference Hold Time

Droop Quantity

Droop Delay Time

Dwell Reference @ Start

Dwell Time @ Start

Dwell Reference @ Stop

Dwell Time @ Stop

S-Curve Accel @ Start

S-Curve Accel @ End

S-Curve Decel @ Start

S-Curve Decel @ Stop

Carrier Frequency Max

Carrier in Tune

Input Voltage

Motor Selection

V/F Selection

Max Frequency

Max Voltage

Base Frequency

Min Frequency

Mid Frequency B

Mid Voltage B

Base Voltage

Motor Rated Full Load Amps

Motor Rated Slip

No load current

Number of Poles

0

10

0

0.0

0.05

0.0

0.0

0.0

0.0

1.50

1.50

1.50

5-56

5-57

5-57

5-57

0.00

4

5-57

5-59

0 5-60

230/460 5-61

5-53

5-53

5-53

5-55

5-55

5-56

5-56

5-56

0

1

400

0

20

0.500

0.004

0.0

Factory

Default

0.05

100

15.0

1

30

0.500

5-52

5-52

5-52

5-52

5-52

5-52

5-52

5-53

Ref

Page#

5-48

5-48

5-48

5-50

5-50

5-50

0.0

---

---

---

---

60

0.0

0.0

0.0

1

F

5-62

5-62

60.0

5-62

230/460 5-62

5-62

5-62

5-62

5-62

5-62

5-63

5-63

5-63

5-63

F1-04

F1-05

F1-06

F1-07

F1-08

F1-09

F1-10

F1-11

E5-01

E5-02

E5-03

E5-05

E5-06

F1-01

F1-02

F1-03

E3-02

E4-01

E4-02

E4-03

E4-04

E4-05

E4-06

E4-07

No.

E2-05

E2-06

E2-07

E2-08

E2-09

E3-01

F1-12

F1-13

F1-14

F1-15

F2-01

F3-01

F4-01

F4-02

F4-03

F4-04

F5-01

F5-02

F6-01

Parameter Name

Terminal Resistance

Leakage Inductance

Saturation Compensation 1

Saturation Compensation 2

Mechanical Loss

Motor 2 Control Method

Motion 2

V/F 2 Max Frequency

V/F 2 Max Voltage

V/F 2 Base Frequency

V/F 2 Mid Frequency

V/F 2 Mid Voltage

V/F 2 Min Frequency

V/F 2 Min Voltage

Motor 2 Rated Full Load Amps

Motor 2 Rated Slip

Motor 2 No Load Current

Motor 2 Terminal Resistance

Motor 2 Leakage Inductance

PG Pulses/Revolution

PG Feedback Loss Select

PG OverSpeed Select

Action @ PG Deviation Select

PG Rotation Select

PG Output Ratio

PG Ramp PI/I Select

PG OverSpeed Level

PG OverSpeed Time

PG Deviate Level

PG Deviate Time

SFS Deviate

PG # Gear Teeth 1

PG # Gear Teeth 2

PGO Detect Time

AI-14 Input Select

Digital Input Setup

Analog Out Channel 1 Select

Analog Out Channel 1 Gain

Analog Out Channel 2 Select

Analog Out Channel 2 Gain

Digital Out Channel 1 Select

Digital Out Channel 2 Select

DO-08 Select

0

1

3

0.50

0

120.0

0

0

2.0

0

0

2

1.00

115

0.0

10

0.5

1

0

1

0

---

---

---

---

1

1

---

1024

---

---

---

2

Factory

Default

---

---

1

60

5-64

5-64

230/460 5-64

60 5-64

3.0

12.6

0.5

2.3

5-64

5-64

5-64

5-64

Ref

Page#

5-63

5-63

5-63

5-63

5-63

5-64

5-66

5-66

5-66

5-67

5-67

5-67

5-67

5-67

5-65

5-65

5-65

5-65

5-65

5-66

5-66

5-66

5-67

5-67

5-67

5-67

5-67

5-68

5-69

5-69

5-69

5-69

5-70

5-70

5-71


A-11

H4-01

H4-02

H4-03

H4-04

H4-05

H4-06

H4-07

H5-01

H3-05

H3-06

H3-07

H3-08

H3-09

H3-10

H3-11

H3-12

H1-06

H2-01

H2-02

H2-03

H3-01

H3-02

H3-03

H3-04

No.

F7-01

H1-01

H1-02

H1-03

H1-04

H1-05

H5-02

H5-03

H5-04

H5-05

L1-01

L1-02

L3-04

L4-01

L4-02

L4-03

L4-04

L4-05

L6-01


A-12

Parameter Name

PO-36F Select

Terminal 3 Select

Terminal 4 Select

Terminal 5 Select

Terminal 6 Select

Terminal 7 Select

Terminal 8 Select

Terminal 9 Select

Terminal 25 Select (G5OUT1)

Terminal 26 Select (G5OUT2)

Terminal 13 Signal

Terminal 13 Gain

Terminal 13 Bias

Terminal 16 Signal

Terminal 16 Select

Terminal 16 Gain

Terminal 15 Bias

Terminal 14 Signal

Terminal 14 Select

Terminal 14 Gain

Terminal 14 Bias

Filter Average Time

Terminal 21 Select

Terminal 21 Gain

Terminal 21 Bias

Terminal 23 Select

Terminal 23 Gain

Terminal 23 Bias

Analog Out Level Select

Serial Comm Address

Serial Baud Rate

Serial Communication Parity

Action @ Serial Fault Select

Serial Fault Enable/Disable

Motor Overload Fault Select

Motor Overload Time Constant

Stall Prevention Decel Select

Speed Agree Level

Speed Agree Width

Speed Agree Level +/-

Speed Agree Width +/-

Reference Loss Select

Torque Detection 1 Select

5-82

5-82

5-82

5-83

5-83

5-83

5-83

5-83

5-81

5-81

5-81

5-81

5-82

5-82

5-82

5-82

5-73

5-76

5-76

5-76

5-81

5-81

5-81

5-81

Ref

Page#

5-72

5-73

5-73

5-73

5-73

5-73

5-83

5-83

5-83

5-83

5-84

5-84

5-85

5-87

5-87

5-87

5-88

5-88

5-89

2

1.00

0.0

3

1.00

0.0

0

1F

0

100.0

0.0

2

1F

100.0

0.0

0.00

E

0

0

7F

0

100.0

0.0

0

1

7

9

24

1

0

Factory

Default

1

1.0

0

0.0

1

1

3

0

2.0

0.0

2.0

0

0

O2-04

O2-05

O2-06

O2-07

O2-08

O3-01

O3-02

U1-01

O1-01

O1-02

O1-03

O1-04

O1-05

O2-01

O2-02

O2-03

L8-03

L8-10

L8-14

L9-01

L9-02

L9-03

L9-04

L9-05

No.

L6-02

L6-03

L6-04

L6-05

L6-06

L8-02

U1-02

U1-03

U1-04

U1-05

U1-06

U1-07

U1-08

U1-09

U1-10

U1-11

U1-12

U1-13

U1-14

Parameter Name


Torque Detection1 Time

Torque Detection 2 Select


Torque Detection 2 Time

Over Heat Pre-Alarm Level

Over Heat Pre-Alarm Select

Ground Fault Enable/Disable

UV3 Enable/Disable

Auto Reset Enable/Disable

Reset Attempts

Reset Time

Reset Fault Select 1

Reset Fault Select 2

User Monitor Select

Power On Monitor

Display Scaling

Display Units

Address Display

Mode/Service Key

Operator Stop Key

User Defaults

KVA Selection

Up/Down Frequency Reference

Operator Detection

Elapsed Time Set

Elapsed Time Run

Clear History 1

Clear History 2

Frequency Reference

Output Frequency

Output Current

Control Method

Motor Speed

Output Voltage

DC Bus Voltage

Output kWatts

Torque Reference

Input Terminal Status

Output Terminal Status

Inverter Control Status 1

Elapsed Time

Flash ROM Software ID Number

5-98

5-99

5-99

5-99

5-99

5-100

5-100

5-101

5-95

5-96

5-96

5-97

5-97

5-97

5-97

5-97

5-92

5-92

5-92

5-93

5-93

5-93

5-93

5-93

Ref

Page#

5-90

5-90

5-91

5-91

5-91

5-92

5-101

5-101

5-101

5-101

5-101

5-101

5-101

5-101

5-101

5-101

5-101

5-101

5-101

---

0

0

—

---

0

1

---

0

0

0

0

0

0

6

2

0

1

3

1

3

0.5

1

00080

0

150

0.1

95

Factory

Default

150

0.1

—

—

—

—

—

—

—

—

—

—

—

—

—


A-13

U2-04

U2-05

U2-07

U2-08

U2-09

U2-11

U2-12

U2-13

U1-29

U1-32

U1-33

U1-34

U1-35

U2-01

U2-02

U2-03

U1-21

U1-22

U1-23

U1-24

U1-25

U1-26

U1-27

U1-28

No.

U1-15

U1-16

U1-17

U1-18

U1-19

U1-20

U3-01

U3-02

U3-03

U3-04

U3-05

U3-06

U3-07

U3-08

U3-09

U3-10


A-14

Parameter Name

Terminal 13 Level

Terminal 14 Level

Terminal 16 Level

Motor Secondary Current

Motor Excitation Current

SFS Output

ASR Input

ASR Output

Speed Deviation

PID Feedback

G5IN4 Monitor

Voltage Reference (Vq)

Voltage Reference (Vd)

CPU ID

Load Weight

ACR (q) Output

ACR (d) Output

OPE Detected

Friction Torque

Current Fault

Last Fault

Frequency Reference

Output Frequency

Outut Current

Output Voltage

DC Bus Voltage

Output kWatts

Input Terminal Status

Output Terminal Status

Inverter Status

Last Fault

Fault Message 2

Fault Message 3

Fault Message 4

Elapsed Time 1

Elapsed Time 2

Elapsed Time 3

Elapsed Time 4

AC Operations

OL/LC Count

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-101

5-101

5-101

5-101

5-101

5-101

5-101

5-101

Ref

Page#

5-101

5-101

5-101

5-101

5-101

5-101

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

5-102

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

Factory

Default

—

—

—

—

—

—

—

—

—

—

—

—

—

Electromotive Systems IMPULSE•VG+ Series 2 crane control Instruction manual

Assistant Bot

DANGER, WARNING, CAUTION, and NOTE Statements

DA N G E R

WA R N I N G

C AU T I O N

Contents

Chapter 1: Introduction

Chapter 2: Installation

Chapter 3: Wiring

Chapter 4: Programming Basic Features

Chapter 5: Programming Advanced Features

Chapter 6: Troubleshooting IMPULSE•VG+ Series 2

Appendix A: Servicing IMPULSE•VG+ Series 2

Welcome!

Identifying Your Drive

IMPULSE

Introduction

WA R N I N G

Introduction

Assessing the System Requirements

Assessing the Drive Environment

IMPULSE•VG+ Series 2 General Specifications

230V Class

460V Class

575V Class

230V, 460V and 575VClasses

DBU & CDBR Units

DBU Specifications

External DBU Dimensions

Minimum Resistor Ohmic Values

External Dynamic Braking Unit Specifications

CDBR Braking Unit Specification

AC Reactor Specifications

460V Class

575V Class

Interface Cards Specifications

Interface Card Specification

Installation

WA R N I N G

Choosing a Location

IMPULSE•VG+ Series 2 System Components And External Devices

Long Time Storage

Installing the Drive

IMPULSE•VG+ Series 2 Dimensions/Heat Loss—Open Chassis

IMPULSE•VG+ Series 2 Dimensions/Heat Loss—Open Chassis

IMPULSE•VG+ Series 2 Dimensions/Heat Loss—Open Chassis

Wiring

IMPULSE•VG+ Series 2 Wiring Practices

W A R N I N G

IMPULSE•VG+ Series 2 Standard Connection Diagram

Suggested Circuit Protection Specifications and Wire Size

C A U T I O N :

Inverse Time

Inverse Time

Power Circuit Wiring Procedures

Installation/Wiring of CDBR Braking Unit

W A R N I N G

r

l

l

l

230 V Class Terminal Functions

460 V Class Terminal Functions

575 V Class

External Dynamic Braking Unit (DBU)

External Dynamic Braking Resistor

Grounding

Power Circuit Wiring Diagrams

Detailed Power Circuits—By Model

Wiring the Control Circuit

Control Input

Additional Input Terminals

Control Output

Control Circuit Terminals

Control Circuit Wiring Procedures

R-C Surge Absorber Selection

Electric Brake Coil and Reattachment

Cover and Keypad

Wiring the Encoder Circuit