1. Enabling Objective 1.3 Describe the Design of the Magnetek Impulse VG+ series 3 Variable Frequency Drive Controller

2. IMPULSE ® Drive IMPULSE ® Controls Advantages 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

3. IMPULSE ® Drive IMPULSE ® Controls Advantages 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

4. IMPULSE ® Drive IMPULSE ® Controls Advantages Inverter Output Frequencies > 60Hz are Possible Retrofit Existing AC Equipment Motor Insulation class should be considered

5. Brake Set Delay Timers Ultra Lift™ Slip Compensation Stall Prevention Alternate Acceleration/Deceleration Micro-Positioning Control™ Built-In Auto-Tuning IMPULSE ® VG+ Series 3 Software Features IMPULSE ® Drive

6. 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

7. 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

8. 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

9. 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

10. Adjusts Torque Producing Current without Increasing Magnetizing Current IMPULSE ® VG+ Series 3 Theory of Operation IMPULSE ® Drive

11. In Simple Terms The VG+ series 3 controller is basically a 3 phase AC voltage to DC voltage to 3 phase AC voltage converter. It starts by receiving 480Vac power and utilizes a 3 phase rectifier to supply a DC bus.

12. IMPULSE ® Drive AC to Dc Conversion AC INPUT DC BUS

13. The DC bus is then applied to an Output Transistor assembly to produce square wave pulses. These pulses are modulated and become additive to produce an output voltage at the desired frequency and amplitude. A basic bidirectional Inverter…

14. IMPULSE ® Drive DC to AC conversion Gate Drive Board DC Bus

15. IMPULSE ® Drive PWM Inverter

16. IMPULSE ® Drive PWM Inverter

17. IMPULSE ® Drive 3-Phase PWM

18. IMPULSE ® Drive PWM Waveforms

19. Load Reactors Load Reactors (Coils) are utilized to protect the drive unit from collapsing motor fields or short circuits and they improve the efficiency by creating a more perfect sine wave.

20. IMPULSE ® Drive Selecting Line/Load Reactors Load 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

21. The Rectifier section of the Drive is energized when power is applied to the crane and remains so. When a drive signal is called upon to start and run a motor, a 3 phase output is developed and delivered to the motor. IMPULSE ® VG+ Series 3 Theory of Operation IMPULSE ® Drive

22. Flux Vector “A Vector Drive uses feedback of various real world information (encoder and CT’s) to further modify the PWM pattern to maintain more precise control of the desired operating parameter, be it current, speed or torque. Using a more powerful and faster microprocessor, it uses the feedback information to calculate the exact vector of voltage and frequency to attain the goal. In a true closed loop fashion, it goes on to constantly update that vector to maintain it. It tells the motor what to do, then checks to see if it did it, then changes its command to correct for any error.”

23. Flux Vector “A true closed Loop Vector Drive can also make an AC motor develop continuous full torque at zero speed. This makes them suitable for crane and hoist applications where the motor must produce full torque before the brake is released or else the load begins dropping and it can't be stopped. Closed Loop is also so close to being a servo drive that some people use them as such. The shaft encoder can be used to provide precise travel feedback by counting pulses”

24. Flux Vector Control Typical IMPULSE ® Drive

25. Light Load IMPULSE ® Drive

26. Heavy Load IMPULSE ® Drive

27. Dynamic Braking When slowing down of stopping a motor, Dynamic Braking is utilized. Dynamic Braking occurs when the applied frequency/voltage delivered to the stator is lowered. Due to inertia, the rotor speed can now be faster than the delivered stator speed which results in the motor becoming a generator. Since Generated Voltage is proportional to Speed “N”(differential or slip) times the Magnetic Flux “O” a voltage is now delivered back through the inverter section to the DC bus. Eg = O field X N differential

28. Dynamic Braking A Dynamic Braking Unit is connected across the +/- DC bus and this acts to dissipate the energy and limit the rise of DC voltage. –Without the Dynamic Braking resistor, damage would occur to the drive unit.

29. With Dynamic Braking

30. IMPULSE ® Drive V/F Ratio

31. IMPULSE ® Drive V/F Curve

32. IMPULSE ® Drive Torque & Horsepower vs. Speed

33. IMPULSE ® Drive Theoretical V/F Ratio w/Voltage Boost

34. 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

35. IMPULSEVG+ Series 3 PG-T2 Board IMPULSE ® Drive

36. PG-X2 Card Inputs/Test Points IMPULSE ® Drive

37. 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

38. 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 Line Reactors