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Instruction Manual INSTRUCTION MANUAL Software #14704.x & 14750.X September 2012 Part Number: 144-23910 R3 © Copyright 2012 Magnetek ©2012 MAGNETEK All rights reserved. This notice applies to all copyrighted materials included with this product, including, but not limited to, this manual and software embodied within the product. This manual is intended for the sole use of the persons to whom it was provided, and any unauthorized distribution of the manual or dispersal of its contents is strictly forbidden. This manual may not be reproduced in whole or in part by any means whatsoever without the expressed written permission of Magnetek. Parts of this product may be covered by one or more of the following patents: 121,334,911; 6,653,804; 7,190,146; 111,585,671; 6,956,399; 6,598,859. 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. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTE: A NOTE statement is used to notify installation, operation, programming, or maintenance information that is important, but not hazard-related. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - September 2012 i Disclaimer of Warranty Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of a drive by untrained personnel. A drive should only be programmed by a trained technician who has read and understand the contents of this manual. Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or performance of the drive. This may result in damage to equipment or personal injury. Company shall not be liable for economic loss, property damage, or other consequential damages or physical injury sustained by the purchaser or by any third party as a result of such programming. Company neither assumes nor authorizes any other person to assume for Company any other liability in connection with the sale or use of this product. WARNING Improper programming of a drive can lead to unexpected, undesirable, or unsafe operation or performance of the drive. Service Information For questions regarding service or technical information contact: 1.866.MAG.SERV (1.866.624.7378) World Headquarters Magnetek, Inc. N49 W13650 Campbell Drive Menomonee Falls, WI 53051 1.800.288.8178 Magnetek, Inc. has additional satellite locations for Canada and the United States. For more information, please visit http://www.magnetekmh.com. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - September 2012 ii Contents: DANGER, WARNING, CAUTION, and NOTE Statements. i-i Disclaimer of Warranty . i-ii Service Information . i-ii Chapter 1: Introduction IHow to Use This Manual . 1-4 Introduction . 1-5 IMPULSE®•G+ & VG+ Series 4 General Specifications. 1-6 Chapter 2: Installation IMPULSE®•G+ & VG+ Series 4 System Components And External Devices . 2-4 Long Time Storage . 2-5 Installing the Drive . 2-7 Drive Derating Data . 2-10 Chapter 3: Wiring IMPULSE®•G+ & VG+ Series 4 Wiring Practices. 3-3 Suggested Circuit Protection Specifications and Wire Size . 3-6 Wiring the Encoder Circuit . 3-21 Chapter 4: Getting Started Overview . 4-3 Using the Keypad . 4-4 Auto-Tuning . 4-16 Chapter 5: Programming Advanced Features Introduction . 5-3 Application . 5-3 Special Functions . 5-15 Tuning . 5-52 Motor Parameters . 5-66 Option Card Parameters . 5-72 Terminal Parameters. 5-83 Protection Parameters . 5-101 Operator Parameters . 5-116 Monitor Parameters . 5-126 Chapter 6: Troubleshooting Troubleshooting the Drive. 6-3 Troubleshooting Encoder Related Faults . 6-14 Fault Display and Corrective Actions at Auto-tuning. 6-19 Troubleshooting Option Card Related Faults . 6-21 Copy Function Related Faults. 6-23 Power Section Check . 6-25 S4IF Replacement Procedure. 6-26 Appendix A: Parameter Listing IMPULSE®•G+ & VG+ Series 4 Parameter Listing . A-3 IMPULSE®•G+ & VG+ Series 4 Instruction Manual - September 2012 This page intentionally left blank. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - September 2012 Chapter 1 Introduction This page intentionally left blank. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - September 2012 1-2 WARNING Do not touch any circuitry components while the main AC power is on. In addition, wait until the red “CHARGE” LED is out before performing any service on that unit. It may take as long as 5 minutes for the charge on the main DC bus capacitors to drop to a safe level. Do not check signals during operation. Do not connect the main output terminals (U/T1, V/T2, W/T3) to the incoming, three-phase AC source. Before executing a rotational Auto-Tuning, ensure that the motor is disconnected from the drive train and the electric brake is released. If the electric brake cannot be released, you must ensure that the brake is disengaged for the entire tuning process. Read and understand this manual before installing, operating, or servicing this drive. All warnings, cautions, and instructions must be followed. All activity must be performed by qualified personnel. The drive must be installed according to this manual and local codes. Do not connect or disconnect wiring while the power is on. Do not remove covers or touch circuit boards while the power is on. Do not remove or insert the digital operator while power is on. Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply is turned off. The charge indicator LED will extinguish when the DC bus voltage is below 50 VDC. To prevent electric shock, wait at least five minutes after all indicators are OFF and measure DC bus voltage to confirm safe level. Do not perform a withstand voltage test on any part of the unit. This equipment uses sensitive devices and may be damaged by high voltage. The drive is suitable for circuits capable of delivering not more than 100,000 RMS symmetrical Amperes. Install adequate branch circuit short circuit protection per applicable codes. Failure to do so may result in equipment damage and/or personal injury. Do not connect unapproved LC or RC interference suppression filters, capacitors, or overvoltage protection devices to the output of the drive. These devices may generate peak currents that exceed drive specifications. IMPULSE®•G+ & VG+ Series 4 Instruction Manual - September 2012 1-3 How to Use This Manual This manual provides technical information on IMPULSE®•G+ and VG+ Series 4 parameter settings, drive functions, troubleshooting, and installation details. Use this manual to expand drive functionality and to take advantage of higher performance features. This manual is available for download on the Magnetek Material Handling document center website at www.magnetekmh.com. The IMPULSE®•G+ and VG+ Series 4 drives share a common power section, and similar parameters. The parameters and performance differ because the VG+ drives includes a PG-X3 encoder feedback card allowing the drive to perform Flux Vector control of the motor. The G+ drives operate in V/f or Open Loop Vector control modes, appropriate for traverse or standard hoist motions. The VG+ drives are typically applied to the non-mechanical load brake hoist motion, and can be applied to traverse motions where torque control or a wide speed control range is required. Many IMPULSE®•G+ and VG+ Series 4 parameter functions are common between the two drive classes. The functions that differ are noted with a “Model” column; this column designates which parameters are available for a given function. Functions may also be control method dependant; these differences are noted in the function and parameter details. Table 1-1 below notes which drives can operate in a.
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