impulse ® adjustable frequency drives technical training program
TRANSCRIPT
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