Home / CRANE INVERTER / Magnetek / Inverter-Crane Magnetek G+/VG+ Series 4 Repairs Precision Zone

Precision Zone Expertly Repairs Inverter-Crane Magnetek G+/VG+ Series 4

Here at Precision Zone, one of our specialties is the repair services of Magnetek inverter units. One series that we often work on is the G+ and VG+ Series 4 series.

This series of inverters offered by Magnetek is considered general purpose, though they are primarily used in crane application, and has a wide range of models to cover a large array of applicable systems. Input ratings are offered in 230VAC, 460VAC, and 575VAC options and rated amperage can range from 1 amp all the way up to 605 amps. In addition to the multiple input ratings, this series is UL, cUL, CSA, and RoHS certified, with CE available upon request.

These units come equipped with a five line, 16-character digital operator which is easily accessible and embedded on the front cover. This operator allows the user to monitor drive operations, view and edit parameters, and also view fault codes to assist with troubleshooting, if the need arises. Below it can be seen which output ratings are available depending on the available input voltage.

In the chart below, a filled cell indicates the rated output is available with the corresponding input voltage.

Rated Input Voltage
vs.
Rated Output Amps		 230VAC 460VAC 575VAC
1A
3A
4A
5A
6A
7A
8A
9A
11A
12A
14A
17A
18A
22A
24A
25A
27A
31A
32A
33A
39A
41A
45A
47A
52A
60A
62A
75A
77A
85A
91A
99A
112A
115A
130A
145A
150A
172A
180A
200A
215A
216A
260A
283A
304A
346A
370A
415A
450A
605A

Transistion guides to convert a system using a series 2 or series 3 of G+ or VG+ of inverters can be found below

Series 2 to Series 4 Transition Guide

Series 3 to Series 4 Transition Guide

When assessing the functionality of a Magnetek Crane Inverter, our expert repair team of engineers and technicians conducts a four-step check:

    1. Visual Overview
    2. Static Test
    3. Checks Under Power
    4. Alarm Codes Verification

This overview is Precision Zone's basic troubleshooting process. Once our repair team starts on the job, we use specialized and customized testing fixtures, Huntron trackers, signal generators, oscilloscopes, milli and megaohm meters, as well as any other necessary tools we have available to assure quality repair work. Most importantly, every repair is fully tested in our custom-built simulators under load with a motor to replicate real-life working environment.

Precision Zone goes as far as using heating chambers and overnight dynamic testing, when applicable, to guarantee performance of the repaired product when it arrives back with the customer.

Repair Process for Crane Inverter Drives

Visual Overview

When conducting a visual check, the technician inspects the drive for any mechanical damage to the drive itself and any printed circuit boards (PCB). The technician then proceeds to verify connections are tight and correct inside the drive and there are no loose screws, wires or debris. Additionally, the unit is checked for any burn marks on the components, PCBs or chassis. During the visual inspection, excessive dirt on cooling components is noted as well as the functionality of the heat sink.

Basic Static Check

Input Module Testing

The input modules on these units can be tested by use of a digital multimeter with diode checking capabilities. Upon removing the cover, all of these terminals can be located along the terminal strip found within the unit.

Positive Lead Negative Lead Reading
R '+1' or '+2' Terminal 0.42V-0.54V
S '+1' or '+2' Terminal 0.42V-0.54V
T '+1' or '+2' Terminal 0.42V-0.54V
'-' Terminal R 0.42V-0.54V
'-' Terminal S 0.42V-0.54V
'-' Terminal T 0.42V-0.54V

Output Module Testing

Using the same type of test as above, the output modules can be checked as well. Our technicians are also equipped with huntron devices further verify their integrity.

Positive Lead Negative Lead Reading
U '+1' or '+2' Terminal 0.40V-0.46V
V '+1' or '+2' Terminal 0.40V-0.46V
W '+1' or '+2' Terminal 0.40V-0.46V
'-' Terminal U 0.40V-0.46V
'-' Terminal V 0.40V-0.46V
'-' Terminal W 0.40V-0.46V

Common Alarms for the Magnetek G+/VG+ Series 4 Crane Inverter Units

Alarm Code Description Checks
OC Overcurrent detected on the output exceeding 200% of drive unit's rated output current
  • Check cables for poor insulation
  • Perform magaohm test on motor
  • Use 'Output Module Testing' test to verify modules
  • Check for ground faults
GF Ground fault has been detected on the output
  • Perform Megohm test on motor with cables (disconnected from drive
  • Check output phases of drive to ground for any short
  • Swap drive out with another, if applicable and motor end checks good
EF# External fault occurred on terminal S#. # of EF alarm denotes which terminal has the fault
  • Verify parameters for proper settings
  • Verify terminal matches up with set function (open when meant to be open, closed if meant to be closed, etc.)
  • Verify external connection is not faulty
CPF## A fault has been detected within the control circuitry. Specific CPF alarms point to more specific sections
  • Cycle power, see if alarm persists
  • If parameters are available, attempt to initialize
  • Swap drive with a known working, if applicable


For a full list of Magnetek G+/VG+ Series 4 alarms, see manual below:

https://s3.amazonaws.com/Icarus/DOCUMENTS/Magnetek_Alarms_Faults_3758.pdf

This list of checks for certain alarms is primarily a good starting point and if any further troubleshooting or technical support is needed feel free to contact us via phone or email to get in touch with our experienced tech support team.

Learn the benefit of repairing your Magnetek Crane Inverters with Precision Zone

  • Quick and Flexible Service
  • Fully Refurbished, not just repaired
  • Decades of Industry Experience
  • Superior Technology Knowledge and Support

Contact Us To Start Your Repair Today!


Recently Repaired Products

Magnetek 4045-VG+S4 image 4045-VG+S4 is an
Inverter-Crane manufactured by Magnetek
Discovered issues: Bad Gate Section/Board, Bad Power Section/Board, Bad Capacitor(s), Bad Circuit Board Component(s), Bad Cooling Fans, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Input Voltage: 460V
Rated Output Current: 45A
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Magnetek 4180-G+S4 image 4180-G+S4 is an
Inverter-Crane manufactured by Magnetek
Discovered issues: Leaky Capacitors (Open, Corroded Traces), Bad Capacitor(s), Bad Circuit Board Component(s), Multiple signs of previous repair, Bad Power Section/Board, Bad Cooling Fans, Excessive Dirt/Debris
Input Voltage: 460V
Rated Output Current: 180A
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Magnetek 4024-VG+S4 image 4024-VG+S4 is an
Inverter-Crane manufactured by Magnetek
Discovered issues: Bad Capacitor(s), Bad Circuit Board Component(s), Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Leaky Capacitors (Open, Corroded Traces)
Input Voltage: 460V
Rated Output Current: 24A
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Magnetek 4370-G+S4 image 4370-G+S4 is an
Inverter-Crane manufactured by Magnetek
Discovered issues: Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Section/Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
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Magnetek 4031-VG+S4 image 4031-VG+S4 is an
Inverter-Crane manufactured by Magnetek
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Magnetek 4091-VG+S4 image 4091-VG+S4 is an
Inverter-Crane manufactured by Magnetek
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Magnetek 4018-G+S4 image 4018-G+S4 is an
Inverter-Crane manufactured by Magnetek
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Input Voltage: 460V
Rated Output Current: 18A
Series: Electromotive Impulse G+ Series 4

Magnetek 4150-VG+S4 image 4150-VG+S4 is an
Inverter-Crane manufactured by Magnetek
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Rated Output Current: 150A
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Magnetek 4180-VG+S4 image 4180-VG+S4 is an
Inverter-Crane manufactured by Magnetek
Discovered issues: Passed Testing - Highly Recommend Recondition, Bad Cooling Fans, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces), Missing parts/components, Failure Info Required for Further Evaluation
Input Voltage: 460V
Rated Output Current: 180A
Series: Electromotive Impulse VG+ Series 4

Magnetek 4045-G+S4 image 4045-G+S4 is an
Inverter-Crane manufactured by Magnetek
Discovered issues: Bad Output Transistors/SCRs, Bad Regen Resistor/s
Input Voltage: 460V
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Magnetek 4039-VG+S4 image 4039-VG+S4 is an
Inverter-Crane manufactured by Magnetek
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Rated Output Current: 39A
Series: Electromotive Impulse VG+ Series 4

Magnetek 4014-G+S4 image 4014-G+S4 is an
Inverter-Crane manufactured by Magnetek
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Input Voltage: 460V
Rated Output Current: 14A
Series: Electromotive Impulse G+ Series 4