IMPULSE®

Adjustable Frequency Drives

Technical Training Program

IMPULSE® Drive

Application Questionnaire• Hoist Manufacturer

• Motor Data

• Special Motor Type

• Brake Type

• Facility Data

• New or Existing Application

• Equipment Data

• Other Options Required

IMPULSE® Drive

CMAA Crane Classification

• Class A – Standby/Infrequent Service

• Class B – Light Service

• Class C – Moderate Service

IMPULSE® Drive

CMAA Crane Classification

• Class D – Heavy Service

• Class E – Severe Service

• Class F – Continuous Severe Duty

(Continued)

IMPULSE® Drive

HMI Classification

• H1 – Infrequent Service or Standby

• H2 – Light

• H3 – Standard

• H4 – Heavy

• H5 - Severe

IMPULSE® Drive

Mechanical Load Brake Hoists

IMPULSE® Drive

Mechanical Load Brake Hoists

• Defined by CMAA as a Hoist Control Braking Means

• Controls Load During lowering

• Keeps Load from Falling if Motor Brake Fails

• Supplements the Electric Motor Brake

IMPULSE® Drive

Mechanical Load Brake Hoists

• Applying IMPULSE® Drives:– Use the Standard Hoist Amp-acity Rating

When Selecting a Drive

– Due to Wear of the Mechanical Load Brake, Hoists Require Dynamic Braking Resistors

IMPULSE® Drive

Worm Gear Hoists

IMPULSE® Drive

Worm Gear Hoists

• Considered by CMAA to be Equipped with a Controlled Braking Means

• Common Misconception that all Worm Gears are Self-Locking or Non-Overhauling

IMPULSE® Drive

Worm Gear Hoists

• Applying IMPULSE®

Drives:– Dynamic Braking Resistors Should be Used

on All Worm Gear Hoists

– Extremely Slow Speeds May Not be Achievable

– Program IMPULSE®

G+ Series 3 and IMPULSE

®

P3 to Overcome Lockup at

Start (Voltage Boost)

IMPULSE® Drive

Special Input Power Supplies

• 575 Volt AC (G+/VG+ Series 2 only)

• 250 Volt DC

• Single-Phase

• 25 Hertz

IMPULSE® Drive

Recommended Motor Features

• Squirrel Cage Motor

• NEMA Design B (3 to 5% Slip)

• TENV Enclosure Design

• 60-Minute Time Rating

• Class F Insulation

• Thermostats (Klixons in Stator Windings)

Standard Duty

IMPULSE® Drive

Recommended Motor Features

• All Standard Duty Features

• 1.0 Service Factor on AFD Power

• Temperature Rise over Ambient Rating of Class F (115° C)

Special Duty

IMPULSE® Drive

• Low Speed (3 to 6 Hz) Operation for Extended Periods of Time

• Very Low Speed (1.5 Hz) Operation w/100% Motor Torque, Smooth Shaft Rotation

• CMAA Class E or F Cranes

• High Ambient Temperature Environments

Applications Requiring Inverter Duty Motors

IMPULSE® Drive

Severe Duty Applications May Require

• TEBC Construction or Upsize Frame

• Class H Insulation

• Special Pain Coatings and Shaft Seals

IMPULSE® Drive

Applying NEMA D Motors

IMPULSE® Drive

Applying Wound Rotor Motor

IMPULSE® Drive

Applying Drives w/Existing Motors

• Two-Speed/Two-Winding

• Consequent Pole Motors

• Single-Phase Motors

IMPULSE® Drive

Selecting Line/Load Reactors

• Acts as a Current Limiting Device

• Filters the Waveform and Attenuates Electrical Noise Associated with AFD Output

• Use Continuous Output Rating of the Drive When Selecting Line Reactors

Line Reactors

IMPULSE® Drive

Selecting Line/Load ReactorsLoad Reactors

• Used on the Load Side of the AFD between AFD and Motor

• Protects the Drive under Motor Short Circuit Conditions

• Reactor Attempts to Recreate Perfect Sine Wave, Improves Motor Efficiency

• Use the Full Load Ampere Rating of the Motor When Selecting Load Reactors

IMPULSE® Drive

Input to Single AFD

IMPULSE® Drive

Input to Multiple AFD’s

IMPULSE® Drive

IMPULSE® ControlsAdvantages

• Variable Speed Control w/Single-Speed Motor

• Minimizes High-Starting Current w/Motor

• Adjust Acceleration/Deceleration Rates

• Unique Torque Limit Function

• Creep Speed for Precise Positioning without Plugging

• Can Produce 150% Full Load Torque

IMPULSE® Drive

IMPULSE® ControlsAdvantages

• Inverter Output Frequencies >

60Hz are Possible

• Retrofit Existing AC Equipment

IMPULSE® Drive

IMPULSE® ControlsAdvantages

• Lowers Operating Costs and Minimizes Equipment Downtime

– AC Squirrel Cage Induction Motors for Variable Speed Control Provide Reliability

– Electronic Reversing, Multi-Speed Operation Eliminates Conventional Magnetic Contactors

– Electronic Dynamic Braking Provides Effective Braking without the Use of Mechanical Brakes

IMPULSE® Drive

PWM Inverter

IMPULSE® Drive

AC to Dc Conversion

AC INPUT

DC BUS

IMPULSE® Drive

DC to AC conversion

Gate Drive Board

DC Bus

IMPULSE® Drive

PWM Inverter

IMPULSE® Drive

PWM Inverter

• PWM Output at ~ 6

• PWM Output at ~ 20

• PWM Output at ~ 60

IMPULSE® Drive

3-Phase PWM

IMPULSE® Drive

PWM Waveforms

IMPULSE® Drive

3Ø AC Motors

IMPULSE® Drive

V/F Ratio

IMPULSE® Drive

Theoretical V/F Ratio w/Voltage Boost

IMPULSE® Drive

V/F Curve

IMPULSE® Drive

Torque & Horsepower vs. Speed

Speed Control Method Definitions

• Multi-Step

• Infinitely Variable (2-Step Type)

IMPULSE® Drive

Speed Control Method Definitions

• Infinitely Variable (3-Step Type)

• Analog Speed Reference

• Via PC or PLC for Automation

(Continued)

IMPULSE® Drive

Braking Method Definitions

• Immediate Stop at “Stop” Command

• Decelerate at “Stop” Command

• No-Load Brake Hoist (VG+ Only)

IMPULSE® Drive

IMPULSE®•P3 Series 2• IGBT Output

• CMAA Class A through D

• 40:1 Speed Range in Scalar Mode

• 100:1 in Open Loop Vector Mode

• Ratings:

– 460V AC, ½ to 10 Hp

– 230V AC, ¼ to 10 Hp

• Built-In Holding Brake Relay

IMPULSE® Drive

• Up to 5 Distinct Speeds

• 1- or 3-Step Infinitely Variable Control

• 0-10V DC or 4-20mA Analog Control

• Built-in DB Transistor for Dynamic Braking, Designed to Meet CMAA Class A through D Applications

IMPULSE®•P3 Series 2

IMPULSE® Drive

• Standard 120V AC Interface

• Small Size – Up to 50% Smaller than Previous Models with Optional Heat Sink Design

• Mounting Depth Can Be Reduced by Up to 45%

IMPULSE®•P3 Series 2

IMPULSE® Drive

• X-Press ProgrammingTM

• Safe Operating WindowsTM

• Multiple Speed Control Methods

• Quick StopTM

• Reverse Plug SimulationTM

• Automatic Keypad LockoutTM

IMPULSE®•P3 Series 2Software Features

IMPULSE® Drive

• Motor Thermal Overload Protection

• Swift-LiftTM

• Output Phase Loss Protection

• 3 Programmable Outputs

IMPULSE®•P3 Series 2Software Features

IMPULSE® Drive

• Open Loop Vector Mode Operation – Provides Greater Speed Control (100:1), Less Motor Heating and Lower Power Consumption

• Up to 16 Discrete Speed References

• Expanded Programmable Multifunction Inputs and Outputs

• End of Travel Limit Slow Down and Stop Inputs

IMPULSE®•P3 Series 2Advanced Software Features

IMPULSE® Drive

• Micro-PositioningTM Control

• Serial Communication via ModBus/RS-485

IMPULSE®•P3 Series 2Advanced Software Features

IMPULSE® Drive

• Expanded HP range

– Identical dimensional footprint as the P3 (up to 5HP)

– Smaller footprint beyond 5HP

• Factory Default Software Settings for Basic application programming

• Advanced Programming Capability

IMPULSE®•G+ Mini – New!

IMPULSE® Drive

• Standard 120VAC interface card, 24VAC optional

• Ratings:

– ½ through 20 HP in 380-480V

– ¼ through 20HP in 200-240V

• Optional Flat Heat Sink Design Available

IMPULSE®•G+ Mini – New!

IMPULSE® Drive

• CMAA Class A-D Service

• Exclusive Crane & Hoist Software

• Removable Terminal Block with Parameter Backup

• 40:1 Speed Range

• Safety Features

IMPULSE®•G+ Mini – New!Basic Control Mode

IMPULSE® Drive

• Safety Features– Safe Operating Windows™ – Motor Thermal Overload Protection– Quick Stop™– EN954-1 Safety Category 3, Stop

Category 0

IMPULSE®•G+ Mini – New!Basic Control Mode

IMPULSE® Drive

• Performance Features– X-Press Programming™ – Swift-Lift™ – Reverse Plug Simulation™ – 40:1 Speed Range – Auto-Tuning

IMPULSE®•G+ Mini – New!Basic Control Mode

IMPULSE® Drive

• All the Basic Mode Features, plus:– 100:1 Speed Range– 200% Starting torque at 0.5Hz – Up to 16 Discrete Speed References – Expanded Programmable Input/Output Capabilities – Preferred Parameter feature – Ingenious pre-maintenance function (IGBTs,

Capacitors, FAN)

IMPULSE®•G+ Mini – New!Advanced Control Mode

IMPULSE® Drive

• Performance Features– Open-Loop Vector Control – Micro-Positioning™ Control – Serial Communications – Load Check™ – Inching Control – Auto-Tuning

IMPULSE®•G+ Mini – New!Advanced Control Mode

IMPULSE® Drive

• Easy to read LED 5 digit display

• Program both Basic and Advanced drive parameters

• Monitor the functions of the drive

• Read alpha-numeric fault diagnostic indications

IMPULSE®•G+ Mini – New!Keypad/Digital Display

IMPULSE® Drive

• 40% Smaller Footprint than Previous Models

• Third Generation IGBTs

• CMAA Class A through F

• Scalar Control or Open Loop Vector Modes

• Up to 40:1 – Scalar Mode

• Up to 100:1 – Open Loop Vector Mode

• Keypad w/English Display

IMPULSE®•G+ Series 3

IMPULSE® Drive

• Ratings:

– 230V Series, 1-125 Hp (7-346 AMP)

– 460V Series, 1-500 Hp (2-590 AMP)

– 575V Series, 2-200 Hp (3.5-200 AMP)

• Standard 120V AC Interface

• Built-in DB Transistor to 39 Amps (460V), 58 Amps (230V) and 32 Amps (575V)

• Three Programmable Digital Outputs are Standard

IMPULSE®•G+ Series 3

IMPULSE® Drive

• Six Programmable Digital Inputs

– Additional Four Inputs with Optional Card (G5IN4)

• Three Programmable Analog Inputs

• Two Programmable Analog Outputs

IMPULSE®•G+ Series 3

IMPULSE® Drive

• Built-In Auto-Tuning (Open Loop Only)

• X-Press ProgrammingTM

• Safe Operating WindowsTM

• Multiple Speed Control Methods

• Keypad Copy Function

• Load CheckTM

• Brake Answer Back

IMPULSE®•G+ Series 3

IMPULSE® Drive

• Brake Set Delay Timers

• Torque Proving at Start

• Swift Lift™

• Inching Control

• Slip Compensation

IMPULSE®•G+ Series 3Software Features

• Stall Prevention

• Alternate Acceleration/Deceleration

• Micro-Positioning Control™

• Built-In Auto-Tuning

IMPULSE® Drive

• Quick Stop™

• Reverse Plug Simulation™

• Multi-Level Password

• Motor Thermal Overload Protection

• Motor Phase Loss Detection

• Ground Fault Protection

IMPULSE®•G+ Series 3Software Features

IMPULSE® Drive

• Overload/Load Check Counter

• Number of Operations

• Short Circuit Protection

• Built-In Serial Communication

• Fault history and Tracing via Flash ROM

• Elapsed Run Timer

IMPULSE®•G+ Series 3Software Features

IMPULSE® Drive

• Enhancements – KEYPAD– Series 2 Keypad: 2-16

Character Lines

– Series 3 Keypad: 5-16 Character Lines

IMPULSE®•G+ Series 3 Drives

IMPULSE® Drive

IMPULSE®•G+ Series 3 Drives

IMPULSE® Drive

CUSTOM SOFTWARE

• Sway Control System (SCS®) Series 2

IMPULSE®•G+ Series 3 Drives

IMPULSE® Drive

3 New Options – COMMUNICATIONS– All Series 3 drives offer optional

wireless communication packages for up to 31 drives (nodes) which can provide:

• Drive Operation Monitoring

• Drive Diagnostics

• Drive Programming

IMPULSE®•VG+ Series 3

IMPULSE® Drive

• Third Generation IGBTs

• CMAA Class A through F

• Up to 1000:1 – Closed Loop Vector Mode

• Keypad w/English Display

• Ratings:– 230V Series, 1-125 HP (7-346 AMP)– 460V Series, 1-500 HP (2-590 AMP)– 575V Series, 2- 200 HP (3.5-200 AMP)

(Series 2 drives only)

• Standard 120V AC Interface• Built-In DB Transistor to 39 Amps (460V),

33 Amps (230V) and 58 Amps (575V) (Series 2 drives only)

• Three Programmable Digital Outputs are Standard

IMPULSE®•VG+ Series 3

IMPULSE® Drive

• Six Programmable Digital Inputs and Four Additional Inputs with Optional Card (G5IN4)

• Three Programmable Analog Inputs

• Three Programmable Analog Outputs

IMPULSE®•VG+ Series 3

IMPULSE® Drive

• Built-in Auto-Tuning

• X-Press Programming™

• Safe Operating Windows™

• Multiple Speed Control Methods

• Keypad Copy Function

• Load Check™

• Brake Answer Back

IMPULSE®•VG+ Series 3

IMPULSE® Drive

• Brake Set Delay Timers

• Torque Proving at Start

• Ultra Lift™

• Slip Compensation

• Stall Prevention

• Alternate Acceleration/Deceleration

• Micro-Positioning Control™

• Built-In Auto-Tuning

IMPULSE®•VG+ Series 3

Software Features

IMPULSE® Drive

• Motor Torque Proving at Start

• Roll Back Detection at Start

• Seized Brake Detection at Start

• Brake Proving at Stop

• Torque Limited Load Check™

• Torque Limited Accel and Decel

• Built-In Auto-Tuning

IMPULSE®•VG+ Series 3

Software Features

IMPULSE® Drive

• Quick Stop™

• Reverse Plug Simulation™

• Multi-Level Password

• Motor Thermal Overload Protection

• Motor Phase Loss Detection

• Ground Fault Protection

• Slack Cable Protection

Software Features

IMPULSE®•VG+ Series 3

IMPULSE® Drive

• Overload/Load Check Counter

• Number of Operations

• Short Circuit Protection

• Built-In Serial Communication

• Fault History and Tracing via Flash ROM

• Elapsed Run Timer

Software Features

IMPULSE®•VG+ Series 3

IMPULSE® Drive

• Closed Loop control via Encoder

• Speed Set Points with Torque Limit

• Determines Motor Slip

• Calculates Torque Demand

• Quick Response to Changes in Torque Demand

IMPULSE®•VG+ Series 3

Theory of Operation

IMPULSE® Drive

• Adjusts Torque Producing Current without Increasing Magnetizing Current

IMPULSE®•VG+ Series 3

Theory of Operation

IMPULSE® Drive

• Adjusts Torque Producing Current without Increasing Magnetizing Current

IMPULSE®•VG+ Series 3

Theory of Operation

IMPULSE® Drive

• Snapped Shaft / Drive Train Discontinuity Detection

• Indexing

• Load Sharing

• Electronic Programmable Limit Switches

IMPULSE®•VG+ Series 3

Additional Standard Options

IMPULSE® Drive

• Footbrake/Static Stepless Simulation Software (VG+)

• Hoist / Drive Synchronization Software (VG+)

• Clamshell / Grab Bucket Software (VG+)

• Swing Control Series 2 (SCS-S2) (G+)

Custom Software

IMPULSE® Drive

IMPULSE®•G+/VG+ Series 3 Drives

IMPULSE®•G+/VG+ Series 3 Drives

IMPULSE® Drive

IMPULSE®•G+/VG+ Series 3 Drives

IMPULSE® Drive

IMPULSE®•G+/VG+ Series 3 Drives

IMPULSE® Drive

3 New Options : ADDITIONAL FEATURES– Cooling Fan Operation Select

• Continuous Operation

• Timed Operation – Programmable Time Delay for Cooling Fan Shut-off After Drive Operation

– Maintenance Timer – Can be Programmed to Provide Maintenance Clock.

– Fault History Storage – Will Store Last 10 Fault Events with Time

IMPULSE®•G+/VG+ Series 3 Drives

IMPULSE® Drive

3 Enhancements – SUPPORT TOOLS – IMPULSE®•Link Basic 4.1

– IMPULSE®•Link WDS

• IMPULSE•Link Basic 4.1 and WDS Readily Accept All Series 3 Drive Parameters

– DataLogger® Series 3

• The Series 3 DataLogger® includes Function and Features supports of the Series 2 and Series 3 Drives

Light Load

IMPULSE® Drive

Heavy Load

IMPULSE® Drive

Flux Vector Control Typical

IMPULSE® Drive

Encoder Specifications• Heavy Duty Industrial Type

• Output Resolution – 1,024 Pulses per Revolution

• 12V DC Differential Line Driver Output

• Connected to Motor Shaft to Provide Zero Backlash

• Shielded Cable

IMPULSE® Drive

IMPULSE•VG+ Series 3 PG-T2 Board

IMPULSE® Drive

IMPULSE•VG+ Series 3 PG-Z2 Board

IMPULSE® Drive

Encoder Wiring DiagramEncoder Interface Board Circuitry

IMPULSE® Drive

PG-T2 CARD Encoder Interface Card

PG-X2 Card Inputs/Test Points

IMPULSE® Drive

• Initial Inspection

• Check Programming Parameters

• Check Encoder Connections

• Confirm Rotation of Motor

• Auto Tune Motor

Start-Up Procedure

IMPULSE®•VG+ Series 3

• Take No-Load Reading

• Load Test

• Check Brake Proving

• Save Parameters

IMPULSE® Drive

• Customer Approval

• Final Constant Upload

Start-Up Procedure

IMPULSE®•VG+ Series 3

IMPULSE® Drive

Thank you for your time this week!

IMPULSE® Drive