Falls, WI 53051

Telephone:
800-288-8178

Website:
www.magnetekmh.com
e-mail:
info@magnetekmh.com

Fax Numbers:
Main: 800-298-3503
Sales: 262-783-3510
Service: 262-783-3508





Table of Contents
GENERAL INFORMATION
.......................................................................... 7

Electrical Safety.................................................................................... 7
Warning Symbols
......................................................................... 7

Warnings
...................................................................................... 7

Safety Instructions
....................................................................... 8

Grounding
.................................................................................... 8

Running the Motor
....................................................................... 9

Receiving .............................................................................................. 9
General Information
..................................................................... 9

Receiving Check List
................................................................... 10

Disclaimer of Warranty ......................................................................... 10
Storage ................................................................................................. 10
Long Term Storage
...................................................................... 10

Installation............................................................................................. 11
Mounting
...................................................................................... 11

Control Panel
............................................................................... 11

Wiring
........................................................................................... 11

OPERATING PRINCIPLES
.......................................................................... 12

Principle of Operation ........................................................................... 12
Controller Configurations
............................................................. 13

OmniPulse DDC Hoist Connections and
Controller Diagram
.................................................................... 16

OmniPulse DDC Traverse Connections and
Controller Diagram
.................................................................... 18

Specifications ....................................................................................... 20
Electrical Ratings
......................................................................... 20

Environmental Specifications
....................................................... 21
NEMA 2-3 DriveChasis, Exploded View..
22
NEMA 4-
5 DriveChasis, Exploded View.. 23
Thermal Characteristics Watts/Amps
.......................................... 24

Series Mill Motor Ratings...................................................................... 25
600 Series Mill Motor Ratings
...................................................... 25

800 Series Mill Motor Ratings
...................................................... 26

ELECTRICAL INFORMATION
..................................................................... 28

Control Board Terminals....................................................................... 28
Connector X1
............................................................................... 28

Connector X2
............................................................................... 28

Connector X3
............................................................................... 29

CONTROLLER SETUP
................................................................................ 33

Using the Digital Display....................................................................... 33
Keypad Operation and Navigation
............................................... 33

Charge and Control Indicator Light
.............................................. 34

DDC Menu Map.................................................................................... 35
Parameter Tables ................................................................................. 45
Group A: Monitoring
..................................................................... 45

Group B: Access
.......................................................................... 49

Group C: Controller Rating Setup
................................................ 51

Group D: Protection
..................................................................... 54

Group E: Drive Control Setup
...................................................... 58

Group F: Speed and Torque Settings
.......................................... 67

Group G: I/O Configuration
.......................................................... 70

Group H: Fault History
................................................................. 76

Earlier Printed Circuit Board Revisions
........................................ 83






START-UP PROCEDURES
.......................................................................... 86
Preliminary Checks............................................................................... 86
Operator Controls ................................................................................. 87
Cable Connections ............................................................................... 87
DDC Hoist & Lowering Motions............................................................ 87
DDC Travel Motion ............................................................................... 93
TROUBLESHOOTING
.................................................................................. 98

Fault Codes and Corrective Action....................................................... 98
Transistor and Diode Check................................................................. 103
CHARTS................................................................................................ 104

APPENDIX A MODBUS RTU1 COMMUNICATION
................................. 118






List of Figures
Figure 1:

Pulse Width Modulation ............................................................................ 12

Figure 2:

OmniPulse DDC Configuation as a Hoist Controller................................. 13

Figure 3:

OmniPulse DDC Configuation as a Bridge or Trolley Controller .............. 14

Figure 4:

Arrangement of the Current and Speed Control Functions ...................... 15

Figure 5:

Typical Hoist Diagram ............................................................................... 16

Figure 6:

Typical Hoist Controller Connections........................................................ 17

Figure 7:

Typical Traverse Diagram ......................................................................... 18

Figure 8:

Typical Bridge or Trolley Controller Connections ..................................... 19

Figure 9:

Multi-Step Control Interface 24V DC Logic Connections.......................... 30

Figure 10:

Joystick Control Interface 24V DC Logic Connections ............................. 31

Figure 11:

2-Line x 16-Character LCD ....................................................................... 32

Figure 12:

Display Navigation Map ............................................................................ 34

Figure 13:

Main Display Sub Menu ............................................................................ 35

Figure 14:

Group A: Monitor Sub Menu ..................................................................... 36

Figure 15:

Group B: Access Menu ............................................................................. 37

Figure 16:

Group C: Controller Rating Setup Sub Menu............................................ 38

Figure 17:

Group D: Protection Sub Menu ................................................................. 39

Figure 18:

Group E: Drive Control Setup Sub Menu.................................................. 40

Figure 19:

Group F: Speed and Torque Sub Menu.................................................... 41

Figure 20:

Group G: I/O Configuration Sub Menu...................................................... 42

Figure 21:

Group H: Fault Sub Menu ......................................................................... 43

Figure 22:

T Type and T Time .................................................................................... 63

Figure 23:

Serial Connections .................................................................................... 73

Figure 24:

Interface Circuit Board .............................................................................. 76

Figure 25:

Control Card................... ........................................................................... 77

Figure 26:

External CT Board / Shunt Board.............................................................. 79

Figure 27:

Tach Feedback Connections .................................................................... 81

Figure 28:

Driver Board (used on 200/360 VDC NEMA Size 2 and 3) ...................... 83

Figure 29:

Driver Board (used on 200/360 VDC NEMA Size 4 and 5) ...................... 84

Figure 30:

CUV Fault Control Power Loss.............................................................103

Figure 31:

UV1 Undervoltage Main DC Supply Low..........................................105

Figure 32:

OT1 Heatsink Temperature Exceeded ...................................................107

Figure 33:

SC Short Circuit.............