Magnetek Impulse G+ series 4 User manual

Adjustable Frequency/Vector Crane Controls
Technical Manual
VFD Firmware: 14707 & 14750
Part Number: 144-23910 R8
November 2022
© Copyright 2022 Magnetek

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 2
SERVICE INFORMATION
For questions regarding service or technical information contact:
1.866.MAG.SERV
(1.866.624.7378)
International Service
Outside the U.S. and Canada call +1.262.783.3500, press 3.
Columbus McKinnon Corporation Locations
Magnetek
N49 W13650 Campbell Drive
Menomonee Falls, WI 53051
Telephone: [phone]
E-mail: [e-mail]
Fax Numbers:
Main: 800.298.3503
Sales: 262.783.3510
Service: 262.783.3508
Canada
161 Orenda Road
Unit 1
Brampton, Ontario
L6W 1W3 Canada
Telephone: [phone]
Fax: [phone]
416.424.7617 (24/7 Service pager)
Europe
STAHL CraneSystems GmbH
Telephone: [phone]
E-mail: [email protected]m
Website
https://www.columbusmckinnon.com/magnetek
© 2022 Columbus McKinnon Corporation
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
person(s) 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 the Columbus McKinnon Corporation.
Parts of this product may be covered by one or more of the following patents: 7,190,146, 7,841,583, 8,401,814,
8,669,724, 8,686,670, and 3,017,333 (Canada).

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 3
PRODUCT SAFETY INFORMATION
Magnetek®offers a broad range of radio remote control products, control products and variable frequency drives
(VFD), and industrial braking systems for material handling applications. This manual has been prepared by
Magnetek to provide information and recommendations for the installation, use, operation and service of
Magnetek’s material handling products and systems (Magnetek Products). Anyone who uses, operates, maintains,
services, installs or owns Magnetek Products should know, understand and follow the instructions and safety
recommendations in this manual for Magnetek Products.
The recommendations in this manual do not take precedence over any of the following requirements relating to
cranes, hoists lifting devices or other material handling equipment which use or include Magnetek Products:
• Instructions, manuals, and safety warnings of the manufacturers of the equipment where the Magnetek
Products are used,
• Plant safety rules and procedures of the employers and the owners of the facilities where the Magnetek
Products are being used,
• Regulations issued by the Occupational Health and Safety Administration (OSHA),
• Applicable local, state or federal codes, ordinances, standards and requirements, or
• Safety standards and practices for the industries in which Magnetek Products are used.
This manual does not include or address the specific instructions and safety warnings of these manufacturers or
any of the other requirements listed above. It is the responsibility of the owners, users and operators of the
Magnetek Products to know, understand and follow all of these requirements. It is the responsibility of the employer
to make its employees aware of all of the above listed requirements and to make certain that all operators are
properly trained. No one should use Magnetek Products prior to becoming familiar with and being trained in
these requirements and the instructions and safety recommendations for this manual.
Product Warranty Information
Magnetek, hereafter referred to as Company, assumes no responsibility for improper programming of a VFD by
untrained personnel. A VFD should only be programmed by a trained technician who has read and understands
the contents of this manual. Improper programming of a VFD can lead to unexpected, undesirable, or unsafe
operation or performance of the VFD. 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.
WARRANTY INFORMATION
For information on Magnetek’s product warranties by product type, please visit
https://www.columbusmckinnon.com/magnetek.
WARNING
Improper programming of a VFD can lead to unexpected, undesirable, or unsafe operation or performance of
the VFD.

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 4
DANGER, WARNING, CAUTION and NOTE Statements
Read and understand this manual before installing, operating or servicing this product. Install the product
according to this manual and local codes.
The following conventions indicate safety messages in this manual. Failure to heed these messages could cause
fatal injury or damage products and related equipment and systems.
DANGERS, WARNINGS and CAUTIONS
Throughout this document DANGERS, WARNING and CAUTION statements have been deliberately placed to
highlight items critical to the protection of personnel and equipment.
NOTE: A NOTE statement is used to notify people of installation, operation, programming or maintenance
information that is important, but not hazard-related.
DANGERS, WARNINGS and CAUTIONS SHOULD NEVER BE DISREGARDED.
Registered Trademarks
Trademarks are the property of their respective owners.
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.

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 5
Table of Contents
1 Introduction ....................................................................................................................................................... 8
1.1 How to Use This Manual........................................................................................................................... 9
1.2 General Information ................................................................................................................................ 10
1.2.1 Assessing the System Requirements................................................................................................. 10
1.2.2 Assessing the VFD Environment........................................................................................................ 10
1.3 Specifications.......................................................................................................................................... 11
1.3.1 VFD Specifications ............................................................................................................................. 11
1.3.2 AC Reactor Specifications.................................................................................................................. 14
1.3.3 Interface Board (S4IF) Specifications................................................................................................. 16
1.3.4 S4I and S4IO Option Card Specifications .......................................................................................... 16
2 Installation ....................................................................................................................................................... 17
2.1 Environmental Requirements ................................................................................................................. 17
2.2 System Components .............................................................................................................................. 18
2.2.1 Standard Components ....................................................................................................................... 18
2.2.2 Optional Components......................................................................................................................... 18
2.2.3 As-Required Components .................................................................................................................. 18
2.2.4 Required Control Components........................................................................................................... 18
2.3 Long-Term Storage and Capacitor Reforming........................................................................................ 19
2.3.1 Capacitor Reforming Procedure......................................................................................................... 19
2.4 Installation Orientation ............................................................................................................................ 21
2.5 Recommended Installation Clearances .................................................................................................. 21
2.6 Optional Side-by-Side Installation........................................................................................................... 22
2.7 VFD Derating .......................................................................................................................................... 23
2.7.1 Temperature Derating ........................................................................................................................ 23
2.7.2 Altitude Derating................................................................................................................................. 23
2.8 Dimensions (IP00/Open-Chassis) .......................................................................................................... 24
3 Wiring .............................................................................................................................................................. 28
3.1 Wiring Practices ...................................................................................................................................... 28
3.2 Suggested Circuit Protection and Wire Size........................................................................................... 31
3.3 Power Circuit Wiring ............................................................................................................................... 34
3.3.1 Power Circuit Connection Diagrams .................................................................................................. 35
3.3.2 Power Circuit Terminal Block Diagrams............................................................................................. 38
3.3.3 Insulation Barrier ................................................................................................................................ 40
3.4 Grounding ............................................................................................................................................... 41
3.5 Interface Board (S4IF) ............................................................................................................................ 42
3.5.1 Terminal Block, DIP Switch, and Jumper Diagrams........................................................................... 42
3.5.2 DIP Switch Functions ......................................................................................................................... 43
3.5.3 Sinking/Sourcing Mode for Safe Disable Inputs ................................................................................. 43
3.6 Control Circuit Wiring.............................................................................................................................. 44
3.6.1 Control Circuit Terminal Block Diagrams ........................................................................................... 45
3.6.2 Sinking/Sourcing for Digital Inputs (24 VDC Only) ............................................................................. 46
3.6.3 Safe Disable and Safe Torque Off ..................................................................................................... 47
3.7 Encoder Circuit ....................................................................................................................................... 48
3.7.1 Encoder Circuit Specification and Wiring Procedure.......................................................................... 48
3.7.2 Encoder Wiring Diagram .................................................................................................................... 49
4 Getting Started ................................................................................................................................................ 50
4.1 Overview ................................................................................................................................................. 50
4.1.1 Checks Before Powering.................................................................................................................... 50
4.1.2 Precautions ........................................................................................................................................ 50
4.2 Using the Keypad ................................................................................................................................... 50
4.2.1 Keypad LED and Button Functions .................................................................................................... 51
4.3 Parameters ............................................................................................................................................. 52
4.3.1 Parameter Menus............................................................................................................................... 52
4.3.2 Menu Structure................................................................................................................................... 53

IMPULSE•G+/VG+ Series 4 Technical Manual
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4.3.3 Initial Setup......................................................................................................................................... 55
4.4 Auto-Tuning ............................................................................................................................................ 63
4.4.1 Standard Auto-Tune (T01-01 = 0) ...................................................................................................... 64
4.4.2 Non-Rotational 1 Auto-Tune (T01-01 = 1).......................................................................................... 64
4.4.3 Terminal Resistance Auto-Tune (T01-01 = 2) .................................................................................... 65
4.4.4 Non-Rotational 2 Auto-Tune (T01-01 = 4).......................................................................................... 65
5 Programming Advanced Features................................................................................................................... 66
5.1 Speed Parameters.................................................................................................................................. 66
5.1.1 Speed References.............................................................................................................................. 66
5.1.2 Reference Limits ................................................................................................................................ 68
5.1.3 Run/Reference Source....................................................................................................................... 69
5.1.4 Stop Method ....................................................................................................................................... 70
5.1.5 Motor Rotation Change ...................................................................................................................... 72
5.1.6 Zero-Speed Operation........................................................................................................................ 72
5.1.7 Input Scan Time ................................................................................................................................. 72
5.1.8 Run Select.......................................................................................................................................... 73
5.1.9 Acceleration/Deceleration .................................................................................................................. 75
5.1.10 Accel/Decel Time Switching Frequency ............................................................................................. 76
5.1.11 Jump Frequencies.............................................................................................................................. 77
5.1.12 Field Forcing....................................................................................................................................... 77
5.2 Special Functions ................................................................................................................................... 78
5.2.1 Quick Stop™ ...................................................................................................................................... 79
5.2.2 Reverse Plug Simulation™ ................................................................................................................ 80
5.2.3 Micro-Speed™ ................................................................................................................................... 81
5.2.4 End of Travel Limits............................................................................................................................ 82
5.2.5 Phantom Stop..................................................................................................................................... 82
5.2.6 Load Share (Torque Following).......................................................................................................... 83
5.2.7 Klixon.................................................................................................................................................. 83
5.2.8 Hook Height Measurement................................................................................................................. 84
5.2.9 Electronic Programmable Limit Switches (EPLS) ..............................................................................85
5.2.10 Upper/Lower Limit Bypass ................................................................................................................. 86
5.2.11 Load Float 2 ....................................................................................................................................... 88
5.2.12 Load Check II™.................................................................................................................................. 88
5.2.13 Swift-Lift™ & Ultra-Lift™ .................................................................................................................... 91
5.2.14 Torque Limit ....................................................................................................................................... 94
5.2.15 Anti-Shock .......................................................................................................................................... 96
5.2.16 No-Load Brake Hoist .......................................................................................................................... 98
5.2.17 Emergency Lift ................................................................................................................................. 102
5.2.18 Digital Input (DI-A3, S4I, or S4IO) Option Card Setup ..................................................................... 104
5.2.19 Weight Measurement ....................................................................................................................... 105
5.2.20 Slack Cable Detection ...................................................................................................................... 107
5.2.21 Snap Shaft Detection ....................................................................................................................... 108
5.2.22 Brake Delay Timers.......................................................................................................................... 109
5.2.23 Timer Function ................................................................................................................................. 109
5.2.24 Maintenance Timer........................................................................................................................... 110
5.2.25 Load Share....................................................................................................................................... 110
5.2.26 Inch Control ...................................................................................................................................... 111
5.2.27 Index Control .................................................................................................................................... 112
5.3 Tuning ................................................................................................................................................... 114
5.3.1 DC Injection Braking......................................................................................................................... 114
5.3.2 Motor Slip Compensation ................................................................................................................. 115
5.3.3 Torque Compensation...................................................................................................................... 115
5.3.4 Automatic Speed Regulator (ASR) Tuning....................................................................................... 116
5.3.5 Torque Control ................................................................................................................................. 119
5.3.6 Dwell................................................................................................................................................. 121
5.3.7 S-Curve Acceleration/Deceleration .................................................................................................. 122

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5.3.8 Carrier Frequency ............................................................................................................................ 123
5.3.9 Hunting Prevention........................................................................................................................... 124
5.4 Motor Parameters ................................................................................................................................. 125
5.4.1 Voltage/Frequency (V/f) Pattern....................................................................................................... 125
5.4.2 Motor Setup...................................................................................................................................... 130
5.4.3 Test Mode Configuration .................................................................................................................. 131
5.5 Option Card Parameters....................................................................................................................... 132
5.5.1 Encoder Feedback (PG-X3) Option Card Setup .............................................................................. 132
5.5.2 Analog Input (AI-A3) Option Card Setup .......................................................................................... 134
5.5.3 Analog Output (AO-A3) Option Card Setup ..................................................................................... 134
5.5.4 Digital Output (DO-A3 or S4IO) Option Card Setup ......................................................................... 136
5.5.5 Profibus-DP (SI-P3) Option Card Setup........................................................................................... 138
5.5.6 Ethernet/IP (SI-EN3), PROFINET (SI-EP3), and Modbus TCP/IP (SI-EM3) Option Card Setup..... 140
5.6 Control I/O Parameters ......................................................................................................................... 141
5.6.1 Digital Inputs..................................................................................................................................... 141
5.6.2 F1 and F2 Keys Function Selection ................................................................................................. 145
5.6.3 Digital Outputs.................................................................................................................................. 146
5.6.4 Analog Inputs ................................................................................................................................... 152
5.6.5 Analog Outputs................................................................................................................................. 155
5.6.6 Serial Communication ...................................................................................................................... 157
5.6.7 Pulse Train Input/Output .................................................................................................................. 159
5.7 Protection Parameters .......................................................................................................................... 160
5.7.1 Motor Overload................................................................................................................................. 160
5.7.2 Power Loss Ride Thru...................................................................................................................... 161
5.7.3 Stall Prevention ................................................................................................................................ 162
5.7.4 Speed Agree .................................................................................................................................... 163
5.7.5 Test Mode ........................................................................................................................................ 165
5.7.6 Torque Detection.............................................................................................................................. 165
5.7.7 Hardware Protection......................................................................................................................... 169
5.7.8 Automatic Fault Reset ...................................................................................................................... 171
5.7.9 Fault Latch........................................................................................................................................ 173
5.8 Keypad and VFD Configuration ............................................................................................................ 174
5.8.1 Monitor Selection.............................................................................................................................. 174
5.8.2 VFD and Keypad Selection .............................................................................................................. 177
5.8.3 Maintenance History......................................................................................................................... 180
5.8.4 Copy Function .................................................................................................................................. 181
5.9 Monitors ................................................................................................................................................ 183
6 Troubleshooting ............................................................................................................................................ 190
6.1 Troubleshooting the VFD ...................................................................................................................... 190
6.1.1 Maintenance and Inspection ............................................................................................................ 190
6.2 Troubleshooting Encoder and Brake Faults and Alarms ...................................................................... 204
6.2.1 DEV–Speed Deviation Fault............................................................................................................. 204
6.2.2 PGO-X-S/PGO-X-H–Pulse Generator Signal Fault.......................................................................... 205
6.2.3 BE1–Rollback Fault.......................................................................................................................... 206
6.2.4 BE2–Torque Proving Fault ............................................................................................................... 206
6.2.5 BE3–Brake Release Fault ................................................................................................................ 207
6.2.6 BE6–Brake Proving Alarm................................................................................................................ 208
6.2.7 BE8–Brake Slipping Alarm ............................................................................................................... 209
6.2.8 OC–Over Current Fault .................................................................................................................... 209
6.3 Auto-Tuning Errors ............................................................................................................................... 210
6.4 Option Card Faults................................................................................................................................ 212
6.5 Copy Function Errors ............................................................................................................................ 215
6.6 Power Section Check ........................................................................................................................... 216
6.7 Interface Board (S4IF) Replacement Procedure .................................................................................. 217
Appendix A: Parameter Listing...................................................................................................................... 219
Appendix B: Standards Compliance.............................................................................................................. 238

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 8
1 Introduction
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 VFD. All warnings, cautions,
and instructions must be followed. All activity must be performed by qualified personnel. The VFD 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 keypad 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 VFD 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 VFD. These devices may generate peak currents that exceed VFD specifications.

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 9
1.1 How to Use This Manual
This manual provides technical information on IMPULSE®•G+/VG+ Series 4 VFD (variable frequency drive)
parameter settings, functions, troubleshooting, and installation details. Use this manual to expand the functionality
and to take advantage of higher performance features. This manual is available for download at
www.columbusmckinnon.com/magnetek.
The VFDs share a common power section and similar parameters. The parameters and performance differ
because the VG+ includes a PG-X3 encoder feedback card allowing the VFD to perform Flux Vector control of the
motor. The G+ VFDs operate in V/f or Open Loop Vector control methods, appropriate for traverse or standard
(mechanical load brake) hoist motions. The VG+ VFDs are typically applied to hoists without mechanical load
brakes, and can be applied to traverse motions where torque control or a wide speed control range is required.
Many parameter functions are common between the two VFD classes. The functions that differ by model or control
method are noted in the parameter descriptions. Table 1-1 below lists the available configurations by model.
Table 1-1: Configurations by Model
The instructions in the following chapters apply to most crane, hoist, and monorail applications. However, carefully
evaluate each specific situation and ensure that the National Electric Code (NEC) codes or local wiring practices
are followed.
These chapters explain how to install the VFD and, to some extent, the components that it interconnects. It
explains how to: assess the environment, mount, and wire the VFD. It is important to develop a plan for mounting
and wiring since each task has an effect on the other one. Wiring Practices is included to provide assistance and
reference.
NOTE: If the IMPULSE•G+/VG+ Series 4 is part of a Magnetek motor control panel, reference the
control drawings and this technical manual, as needed.
VFD Model Control Method
(A01-02) Speed Control Range Motion (A01-03)
G+ V/f (0) 40:1 Traverse (0)
Standard Hoist (1)
G+ Open Loop Vector (2) 200:1 Traverse (0)
Standard Hoist (1)
VG+ Flux Vector (3) 1500:1 Traverse (0)
NLB Hoist (2)

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 10
1.2 General Information
1.2.1 Assessing the System Requirements
It is important to know how the VFD will be utilized before installation. Please know the requirements for the
following components:
• Speed control method(s) - i.e. stepped, stepless, infinitely variable
• Braking method(s) - coast to stop, decel to stop, NLB Hoist
• Power source voltage, number of phases, and kVA rating
• Power source location
•Wiresize
• Grounding location and method
• Control wiring sources - i.e., cab, pendant, radio
1.2.2 Assessing the VFD Environment
When choosing a location for IMPULSE•G+/VG+ Series 4, perform the following steps:
1. Ensure that a three-phase 200 to 240 VAC 50/60 Hz power supply is available for a 230 VAC-rated VFD, a
three-phase 380 to 480 VAC 50/60 Hz power supply is available for a 460 VAC-rated VFD, and a 500 to 600
VAC 50/60 Hz power supply is available for a 575 VAC-rated VFD.
2. Ensure the encoder (if required) is compatible with +5 VDC or 12 VDC.
3. If the RMS encoder current requirement is greater than 200 mA, provide an auxiliary power supply.
4. Ensure that the VFD-to-motor wiring distance is less than 150 ft. unless appropriate reactors, filters, and/or
inverter duty motor is used.
5. Ensure that the VFD is protected or isolated from:
• Ambient temperatures outside the range of +14°F to +140°F (-10°C to +60°C).
• Rain or moisture
• Corrosive gases or liquids
• Direct sunlight
• Severe mechanical vibration
6. Ensure that the VFD is housed in an appropriate NEMA-rated enclosure.
7. For severe-duty applications (long lifts, for example), ensure that the VFD control system (including dynamic
braking resistors) is adequately cooled, even though the ambient temperature limit is not exceeded. For more
information, contact Magnetek.

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
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1.3 Specifications
1.3.1 VFD Specifications
Table 1-2: VFD Capacity - Heavy Duty
230 V 460 V 575 V
Model
(-G+/VG+ S4)
Output
Current
(A)
Output
Capacity
(kVA)
Model
(-G+/VG+ S4)
Output
Current
(A)
Output
Capacity
(kVA)
Model
(-G+/VG+ S4)
Output
Current
(A)
Output
Capacity
(kVA)
2003 3.2 1.2 4001 1.8 1.4 5001 1.7 1.7
2005 5.0 1.9 4003 3.4 2.6 5003 3.5 3.5
2007 6.9 2.6 4004 4.8 3.7 5004 4.1 4.1
2008 8.0 3.0 4005 5.5 4.2 5006 6.3 6.3
2011 11.0 4.2 4007 7.2 5.5 5009 9.8 9.8
2014 14.0 5.3 4009 9.2 7.0 5012 12.5 12.5
2017 17.5 6.7 4014 14.8 11.3 5017 17.0 17.0
2025 25.0 9.5 4018 18.0 13.7 5022 22.0 22.0
2033 33.0 12.6 4024 24.0 18.3 5027 27.0 27.0
2047 47.0 17.9 4031 31.0 24.0 5032 32.0 32.0
2060 60.0 23.0 4039 39.0 30.0 5041 41.0 41.0
2075 75.0 29.0 4045 45.0 34.0 5052 52.0 52.0
2085 85.0 32.0 4060 60.0 48.0 5062 62.0 62.0
2115 115 44.0 4075 75.0 57.0 5077 77.0 77.0
2145 145 55.0 4091 91.0 69.0 5099 99.0 99.0
2180 180 69.0 4112 112 85.0 5130 130 129
2215 215 82.0 4150 150 114 5172 172 171
2283 283 108 4180 180 137 5200 200 199
2346 346 132 4216 216 165 - - -
2415 415 158 4260 260 198 - - -
- - - 4304 304 232 - - -
- - - 4370 370 282 - - -
- - - 4450 450 343 - - -
- - - 4605 605 461 - - -
- - - 4810 810 617 - - -
- - - 41090 1090 831 - - -

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
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Table 1-3: VFD Specifications
Specification Specification Value and Information for All Models
Certification UL, cUL, CSA, CE, RoHS
Crane Duty Classification Rated for CMAA Crane Duty Class A - F (or equivalent)
Rated input power supply
230 VAC class: 3-phase 200 to 240 VAC 50/60 Hz
460 VAC class: 3-phase 380 to 480 VAC 50/60 Hz
575 VAC class: 3-phase 500 to 600 VAC 50/60 Hz
Short Circuit Rating The drive is suitable for circuits capable of delivering a maximum of 100,000 RMS
symmetrical Amps.
Control Voltage
120 VAC (50/60 Hz)
42–48 VAC (50/60 Hz)
24 VAC (50/60 Hz)
24 VDC
Allowable input and control voltage
fluctuation +10% or -15% of nominal
Allowable input frequency fluctuation ±5% of nominal
Allowable control frequency fluctuation ±3 Hz of nominal
Control method Fully digital, V/f, open loop vector, or closed loop flux vector control; sine-wave,
pulse-width modulated
Maximum output voltage (VAC)
3-phase 200 to 240 VAC (proportional to input voltage)
3-phase 380 to 480 VAC (proportional to input voltage)
3-phase 500 to 600 VAC (proportional to input voltage)
Rated frequency (Hz) 0 to 150 Hz
Output speed control range FLV: 1500:1; OLV: 200:1; V/f: 40:1
Output frequency accuracy 0.01%—with digital reference command
0.1%—with analog reference command; 10 bits/10 V
Frequency reference resolution Digital: 0.01 Hz; Analog: 1/2048 of max frequency (11 bit and sign bit)
Output frequency resolution 0.001 Hz
Overload capacity 150% of VFD rated load for 1 min
Remote frequency reference sources 0–10 VDC (20k); 4–20 mA (250); ±10 VDC (20k); Serial (RS-485)
Accel/decel times 0.0 to 25.5 sec - 1 set; 0.0 to 6000.0 sec - 3 sets; 8 adjustable parameters
Braking torque 150% or more with dynamic braking
DC Link Choke Models 2085 to 2415, 4045 to 41090, and 5032 to 5200 have a built-in DC link
choke.
Internal Braking Transistor Models 2003 to 2115, 4001 to 4060, and 5001 to 5041 come with an internal braking
transistor (B1 and B2 terminals).
Motor overload protection UL recognized electronic thermal overload relay; field-programmable
Overcurrent protection level (OC1) 200% of VFD rated current
Circuit protection Ground fault and blown-fuse protection
Overvoltage protection level
230 VAC class: Stops when DC bus voltage exceeds approx. 410 VDC
460 VAC class: Stops when DC bus voltage exceeds approx. 820 VDC
575 VAC class: Stops when DC bus voltage exceeds approx. 1040 VDC
Undervoltage protection level
230 VAC class: Stops when DC bus voltage falls below approx. 190 VDC
460 VAC class: Stops when DC bus voltage falls below approx. 380 VDC
575 VAC class: Stops when DC bus voltage falls below approx. 475 VDC
Heatsink overtemperature Thermostat trips at 105°C (221°F)

IMPULSE•G+/VG+ Series 4 Technical Manual
November 2022
Page 13
* 2kHz carrier frequency
** Maximum rated temperature of 65°C at the VFD chassis with factory approved air handling system
Torque limit selection Limiting of Forward, Reverse, and Regen torques; selectable from 0–300%
Stall prevention Functions for accel, decel, at-speed, and constant horsepower region
Other protection features
VG+: Speed deviation, overspeed, mechanical brake failure, output phase loss,
failed-oscillator, encoder disconnect, roll-back detection, micro controller watchdog,
internal braking transistor failure, torque output limit, motor overcurrent, VFD
overcurrent, input phase loss.
G+: Lost output phase, micro-controller watchdog, internal braking resistor failure,
motor overcurrent, VFD overcurrent, input phase loss.
DC bus voltage indication Charge LED is on until DC bus voltage drops below 50 VDC
Location Indoors; requires protection from moisture, corrosive gases, and liquids
Ambient operating temperature -10° to 60°C (14° to 140°F)*
-10° to 65°C (14° to 149°F)**
Storage temperature -20°C to +70°C (-4°F to 158°F)
Humidity 95% relative; non-condensing
Vibration
10 to 20 Hz at 9.8 m/s2
20 to 55 Hz at 5.9 m/s2(Models 2003 to 2180, 4001 to 4150, and 5001 to 5077) or
20 to 55 Hz at 2.0 m/s2(Models 2215 to 2415, 4180 to 4605, and 5099 to 5200)
Elevation Up to 1,000 m without derate, and up to 3,000 m with derate. Derate 1% of the VFD
output current for every 100 m above 1,000 m.
Atmospheric Pressure 0.7 atmosphere (10.3 psi/70.9 kPa) to 1.05 atmosphere (15.4 psi/106.4 kPa)
Orientation Install the VFD vertically to maintain maximum cooling effects.
Specification Specification Value and Information for All Models

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1.3.2 AC Reactor Specifications
Reactors, both as input (line) and output (load) devices, protect variable frequency drives (VFD), motors, and other
load devices against excessive voltage and current.
The following guidelines are recommendations to help determine input and output reactor requirements:
• The following tables are only a guideline. The size of the reactor is based on motor HP.
• Install an input reactor if the power source is greater than 500 kVA.
• Install an output reactor if the distance between the VFD and the motor exceeds 150 feet (45.7 meters).
• Install an output reactor if a device, such as a power limit switch, is used to disconnect the motor from the VFD.
Use a power limit switch early break circuit to fault the VFD.
• Install one output reactor per VFD for a multiple-VFD arrangement requiring reactor protection.
• For a multiple VFD arrangement, an input reactor for each VFD is recommended for optimal protection.
However, if the VFDs are within two VFD sizes of each other, a single input reactor can be used. The reactor
must be rated at amperage equal to or greater than the sum of the amperage for all the VFDs.
• Reactors are most effective when the reactor current rating approaches the VFD current rating.
Table 1-4: 230 V Class
VFD Model Number Reactor Part Number Reactor Fundamental Amps Motor HP (kW)
2003-G+/VG+S4 REA230-1 4 1 (0.75)
2005-G+/VG+S4 REA230-1 4 1 (0.75)
2007-G+/VG+S4 REA230-2 8 2 (1.5)
2008-G+/VG+S4 REA230-2 8 2 (1.5)
2011-G+/VG+S4 REA230-3 12 3 (2.2)
2014-G+/VG+S4 REA230-3 12 3 (2.2)
2017-G+/VG+S4 REA230-5 18 5 (3.7)
2025-G+/VG+S4 REA230-7.5 25 7.5 (5.6)
2033-G+/VG+S4 REA230-10 35 10 (7.5)
2047-G+/VG+S4 REA230-15 45 15 (11)
2060-G+/VG+S4 REA230-20 55 20 (15)
2075-G+/VG+S4 REA230-25 80 25 (18.5)
2085-G+/VG+S4 REA230-30 80 30 (22)
2115-G+/VG+S4 REA230-40 100 40 (30)
2145-G+/VG+S4 REA230-50 130 50 (37)
2180-G+/VG+S4 REA230-60 160 60 (45)
2215-G+/VG+S4 REA230-75 200 75 (56)
2283-G+/VG+S4 REA230-100 250 100 (75)
2346-G+/VG+S4 REA230-125 320 125 (93)
2415-G+/VG+S4 REA230-150 400 150 (112)

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Table 1-5: 460 V Class
Table 1-6: 575 V Class
VFD Model Number Reactor Part Number Reactor Fundamental Amps Motor HP (kW)
4001-G+/VG+S4 REA460-1 2 1 (0.75)
4003-G+/VG+S4 REA460-2 4 2 (1.5)
4004-G+/VG+S4 REA460-3 4 3 (2.2)
4005-G+/VG+S4 REA460-5 8 5 (3.7)
4007-G+/VG+S4 REA460-5 8 5 (3.7)
4009-G+/VG+S4 REA460-5 8 5 (3.7)
4014-G+/VG+S4 REA460-7.5 12 7.5 (5.6)
4018-G+/VG+S4 REA460-10 18 10 (7.5)
4024-G+/VG+S4 REA460-15 25 15 (11)
4031-G+/VG+S4 REA460-20 35 20 (15)
4039-G+/VG+S4 REA460-25 35 25 (18.5)
4045-G+/VG+S4 REA460-30 45 30 (22)
4060-G+/VG+S4 REA460-40 55 40 (30)
4075-G+/VG+S4 REA460-50 80 50 (37)
4091-G+/VG+S4 REA460-60 80 60 (45)
4112-G+/VG+S4 REA460-75 100 75 (56)
4150-G+/VG+S4 REA460-100 130 100 (75)
4180-G+/VG+S4 REA460-125 160 125 (93)
4216-G+/VG+S4 REA460-150 200 150 (112)
4260-G+/VG+S4 REA460-200 250 200 (150)
4304-G+/VG+S4 REA460-250 320 250 (187)
4370-G+/VG+S4 REA460-300 400 300 (224)
4450-G+/VG+S4 REA460-400 500 400 (298)
4605-G+/VG+S4 REA460-500 600 500 (373)
4810-G+/VG+S4 REA460-750 850 750 (560)
41090-G+/VG+S4 REA460-850 1000 850 (634)
VFD Model Number Reactor Part Number Reactor Fundamental Amps Motor HP (kW)
5001-G+/VG+S4 REA575-1 2 1 (0.75)
5003-G+/VG+S4 REA575-2 4 2 (1.5)
5004-G+/VG+S4 REA575-3 4 3 (2.2)
5006-G+/VG+S4 REA575-5 8 5 (3.7)
5009-G+/VG+S4 REA575-7.5 8 7.5 (5.6)
5012-G+/VG+S4 REA575-10 12 10 (7.5)
5017-G+/VG+S4 REA575-15 18 15 (11)
5022-G+/VG+S4 REA575-20 25 20 (15)
5027-G+/VG+S4 REA575-25 25 25 (18.5)
5032-G+/VG+S4 REA575-30 35 30 (22)
5041-G+/VG+S4 REA575-40 45 40 (30)
5052-G+/VG+S4 REA575-50 55 50 (37)
5062-G+/VG+S4 REA575-60 80 60 (45)
5077-G+/VG+S4 REA575-75 80 75 (56)
5099-G+/VG+S4 REA575-100 100 100 (75)
5130-G+/VG+S4 REA575-125 130 125 (93)
5172-G+/VG+S4 REA575-150 160 150 (112)
5200-G+/VG+S4 REA575-200 200 200 (150)

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1.3.3 Interface Board (S4IF) Specifications
IMPULSE•G+/VG+ Series 4 is designed to interface with user input and output devices through the S4IF interface
board. This eliminates the need for an additional interface relay or isolation circuitry. The S4IF comes in 24 VDC,
24 VAC (50/60 Hz), 42 to 48 VAC (50/60 Hz), and 120 VAC (50/60 Hz) options.
The S4IF has eight optically isolated input terminals which can be used to connect the user input device to the
VFD. The eight terminals are multi-function and programmable.
The S4IF has four 250 VAC, 1.0 Amp relays for output devices. It includes three programmable multi-function
output terminals, and a fault output terminal.
NOTE: The 250 VAC relays on the 120 VAC S4IF boards must be derated to 120 VAC to comply with CE.
Table 1-7: S4IF Ratings
* Certified for CE compliance.
1.3.4 S4I and S4IO Option Card Specifications
IMPULSE•G+/VG+ Series 4 is compatible with AC digital input (S4I) and AC digital input/output (S4IO) option
cards. The option cards expand the I/O capability of the VFD in addition to the I/O on the interface board.
The S4I has four optically isolated input terminals. The S4IO has four optically isolated input terminals and four dry
contact form A relays.
Table 1-8: S4I Ratings
Table 1-9: S4IO Ratings
S4IF Model S1-S8
Voltage Frequency
S4IF-120A60 120 VAC 50/60 Hz
S4IF-120A* 120 VAC 50/60 Hz
S4IF-48A60 42–48 VAC 50/60 Hz
S4IF-24A60 24 VAC 50/60 Hz
S4IF-24D00* 24 VDC -
S4I Model I1-I4
Voltage Frequency
S4I-120A60 120 VAC 50/60 Hz
S4I-48A60 42–48 VAC 50/60 Hz
S4I-24A60 24 VAC 50/60 Hz
S4IO Model I1-I4 O1-O6
Voltage Frequency Voltage (max) Current (max)
S4IO-120A60 120 VAC 50/60 Hz 250 VAC
(120 VAC for CE)/
30 VDC
1.0 AS4IO-48A60 42–48 VAC 50/60 Hz
S4IO-24A60 24 VAC 50/60 Hz

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2 Installation
This chapter explains the following:
• Environmental requirements
• System components
• VFD dimensions
• VFD installation
• VFD derating
2.1 Environmental Requirements
Be sure that the VFD is mounted in a location protected against the following conditions:
• -10°C to +60°C (+14°F to 140°F)*:
• Excessive cold and heat. Use only within the ambient temperature range.
• Direct sunlight (The VFD must be installed inside an enclosure)
• 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 environments
• Combustibles (e.g. thinner, solvents, etc.)
• Physical shock, vibration
• Magnetic noise (e.g. welding machines, power devices, etc.)
* 2 kHz carrier frequency
WARNING
• When preparing to mount the IMPULSE•G+/VG+ Series 4 VFD, lift it by its base. Never lift the VFD by the
front cover, as doing so may cause damage or personal injury.
• Mount the VFD on nonflammable material.
• The VFD generates heat. For the most effective cooling, mount it vertically. For more details, refer to the
“Dimensions (IP00/Open-Chassis)” section in this chapter.
• When mounting units in an enclosure, install a fan or other cooling device to keep the enclosure
temperature below 65°C (149°F)*.
Failure to observe these warnings may result in equipment damage.

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2.2 System Components
2.2.1 Standard Components
• Interface Board (120 VAC, 42-48 VAC, 24 VAC, or 24 VDC)
• PG-X3 Line Driver Encoder Option Card (VG+ only)
2.2.2 Optional Components
• DI-A3 Digital DC Input Option Card
• DO-A3 Digital Output Option Card
• AI-A3 Analog Input Option Card
• AO-A3 Analog Output Option Card
• S4I Digital AC Input Option Card
• S4IO Digital AC Input/Output Option Card
• PS-A10L 24 VDC Control Power Unit for 230 V models
• PS-A10H 24 VDC Control Power Unit for 460 V and 575 V models
• PG-B3 Open Collector Encoder Option Card
• SI-EN3 EtherNet/IP Option Card
• SI-EN3D EtherNet/IP (Dual-Port) Option Card
• SI-EM3 Modbus TCP/IP Option Card
• SI-EM3D Modbus TCP/IP (Dual-Port) Option Card
• SI-EP3 PROFINET Option Card
• SI-P3 PROFIBUS-DP Option Card
2.2.3 As-Required Components
• AC reactor - line or load
• DC bus choke
• External dynamic braking unit
2.2.4 Required Control Components
• External dynamic braking resistor(s)
•Motor
• User input device (pendant, joystick, PC, PLC, radio, or infrared control)
• External circuit protection devices (fuses or circuit breakers). See Section 3.2 on page 31.
• R-C surge suppressors on contactor coils

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2.3 Long-Term Storage and Capacitor Reforming
Powering up the VFD every six months is recommended. Over longer periods of time without power, the VFD’s
electrolytic DC bus capacitors require reformation, especially if stored in an area of high temperatures. Capacitor
reforming is required if VFDs are stored without power for more than 2 to 3 years. This process can be avoided by
powering up the VFD bi-annually for 30 to 60 minutes.
NOTE: Bus cap reforming may not restore full VFD functionality after 2 to 3 years of storage without power.
Variable frequency drives (VFD) contain large bus capacitors that have the potential to be reformed. However,
printed circuit boards also contain electrolytic capacitors that may not function after several years without power.
Magnetek recommends replacing the PCBs should the VFD’s functionality not be restored after bus cap reforming.
Contact Magnetek Field Service for assistance.
The electrical characteristics of aluminum electrolytic capacitors are dependent on temperature; the higher the
ambient temperature, the faster the deterioration of the electrical characteristics (i.e., leakage current increase,
capacitance drop, etc.). If an aluminum electrolytic capacitor is exposed to high temperatures such as direct
sunlight, heating elements, etc., the life of the capacitor may be adversely affected. When capacitors are stored
under humid conditions for long periods of time, the humidity will cause the lead wires and terminals to oxidize,
which impairs their solderability. Therefore, aluminum electrolytic capacitors should be stored at room temperature,
in a dry location and out of direct sunlight.
In the event that a capacitor has been stored in a high ambient environment for more than 2 or 3 years, a voltage
treatment reformation process to electrolytic capacitors should be performed. When stored above room
temperatures for long periods of time, the anode foil may react with the electrolyte, increasing the leakage current.
After storage, the application of even normal voltages to these capacitors may result in higher than normal leakage
currents. In most cases the leakage current levels will decrease in a short period of time as the normal chemical
reaction within the capacitor occurs. However, in extreme cases, the amount of gas generated may cause the
safety vent to open.
Capacitors, when used in VFDs that are stored for long periods of time, should be subjected to a voltage treatment/
reforming process as noted below, which will reform the dielectric and return the leakage current to the initial level.
2.3.1 Capacitor Reforming Procedure
1. Connect the VFD inputs L1 and L2 to a variac. It is also acceptable to use a three-phase variac or a variable
DC power supply rated for the VFD's nominal DC bus voltage.
2. Make sure the variac voltage setting is turned down so that when input power is applied to the variac, the
output of the variac will be at or near 0 volts.
3. Apply power to the variac, listening for abnormal sounds and watching for abnormal visual indications in the
VFD. If the variac has an output current indication, make sure the current is near zero.
4. Slowly turn the variac up, increasing the output voltage to nominal rated input voltage over a time period of 2 to
3 minutes. In other words, ramp the voltage up at a rate of approximately 75 to 100 volts/minute for 230 VAC
units, 150 to 200 volts/minute for 460 VAC units, and 225 to 300 volts/minute for 575 VAC.
5. Let the output voltage remain at rated voltage for 30 to 60 minutes while keeping close watch for abnormal
signs within the VFD. While increasing the variac’s output voltage, the current will momentarily increase as
current is necessary to charge the capacitors.
6. Once 30 to 60 minutes elapse, remove power.
If any abnormal indications occur during this process, it is recommended that the process be repeated. If problems
persist, the VFD should be replaced.

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Figure 2-1: Capacitor Reform Diagrams