Fuji Electric Frenic Mega Series User Manual
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Fuji Electric Frenic Mega Series User Manual

High performance, multifunction inverter
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Summary of Contents for Fuji Electric Frenic Mega Series

  • Page 1 MEHT536a...
  • Page 2 High Performance, Multifunction Inverter User's Manual...
  • Page 3 Copyright © 2010 Fuji Electric Corp. of America All rights reserved. No part of this publication may be reproduced or copied without prior written permission from Fuji Electric Corp. of America. All products and company names mentioned in this manual are trademarks or registered trademarks of their respective holders.
  • Page 4 Preface This manual provides all the information on the FRENIC-MEGA series of inverters including its operating procedure, operation modes, and selection of peripheral equipment. Carefully read this manual for proper use. Incorrect handling of the inverter may prevent the inverter and/or related equipment from operating correctly, shorten their lives, or cause problems.

  • Page 5: Safety Precautions

    Safety precautions Read this manual and the FRENIC-MEGA Instruction Manual (that comes with the product) thoroughly before proceeding with installation, connections (wiring), operation, or maintenance and inspection. Ensure you have sound knowledge of the product and familiarize yourself with all safety information and precautions before proceeding to operate the inverter.
  • Page 6 How this manual is organized This manual contains Chapters 1 through 9, Appendices, Glossary and Index. Chapter 1 INTRODUCTION TO FRENIC-MEGA This chapter describes the features and control system of the FRENIC-MEGA series and the recommended configuration for the inverter and peripheral equipment. Chapter 2 SPECIFICATIONS This chapter describes specifications of the output ratings, control system, and terminal functions for the FRENIC-MEGA series of inverters.
  • Page 7 Appendices Glossary Index Icons The following icons are used throughout this manual. This icon indicates information which, if not heeded, can result in the inverter not operating to full efficiency, as well as information concerning incorrect operations and settings which can result in accidents.
  • Page 8 CONTENTS Chapter 1 INTRODUCTION TO FRENIC-MEGA Features ................................ 1-1 Control System ............................1-15 1.2.1 Theory of inverter ..........................1-15 1.2.2 Motor drive controls.......................... 1-17 External View and Terminal Blocks ...................... 1-18 Recommended Configuration ........................1-20 Chapter 2 SPECIFICATIONS Standard Model 1 (Standard Inverter) ...................... 2-1 2.1.1 Three-phase 230 V class series ......................

  • Page 9: Table Of Contents

    3.1.3.4 Calculating the RMS rating of the motor ..................3-16 Selecting a Braking Resistor........................3-17 3.2.1 Selection procedure ..........................3-17 3.2.2 Notes on selection ..........................3-17 Selecting an Inverter Drive Mode (LD/MD/HD) ..................3-18 3.3.1 Precaution in making the selection ....................3-18 3.3.2 Guideline for selecting inverter drive mode and capacity ..............
  • Page 10 Chapter 5 FUNCTION CODES Overview of Function Codes ........................5-1 Function Code Tables ............................5-2 Function Code Index by Purpose ......................5-36 5.3.1 Configuring the minimal requirements for the inverter to just run the motor ........5-36 5.3.2 Setting up the frequency ........................5-36 5.3.2.1 Frequency setting from the keypad ....................
  • Page 11 6.4.2 V/f control with speed sensor ......................6-8 Vector control with/without speed sensor ....................6-10 PID Process Control Block ........................6-12 PID Dancer Control Block ........................6-14 FM1/FM2 Output Selector ........................6-16 Chapter 7 KEYPAD FUNCTIONS (OPERATING WITH THE KEYPAD) LED Monitor, LCD Monitor, and Keys ....................7-1 Overview of Operation Modes ........................7-4 Running Mode ............................
  • Page 12 Chapter 9 TROUBLESHOOTING Protective Functions ..........................9-1 Before Proceeding with Troubleshooting ....................9-4 If Neither an Alarm Code Nor "Light Alarm" Indication (L-AL) Appears on the LED Monitor ....9-5 9.3.1 Abnormal motor operation ........................9-5 9.3.2 Problems with inverter settings ......................9-12 If an Alarm Code Appears on the LED Monitor ..................
  • Page 13 Chapter 1 INTRODUCTION TO FRENIC-MEGA This chapter describes the features and control system of the FRENIC-MEGA series and the recommended configuration for the inverter and peripheral equipment. Contents 1.1 Features ................................1-1 1.2 Control System..............................1-15 1.2.1 Theory of inverter ........................... 1-15 1.2.2 Motor drive controls..........................

  • Page 15: Features

    1.1 Features 1.1 Features Best vector control for the general-purpose inverter in the class Ideal for highly accurate control such as positioning Vector control with speed sensor Effective for applications requiring highly precise and accurate positioning control such as offset printing Speed control range: 1:1500 Speed response: 100 Hz Speed control accuracy: ±0.01%...
  • Page 16 Fuji's original dynamic torque vector control has further upgraded. Besides the dynamic torque vector control, the inverter is equipped with the motor parameter tuning for compensating even a voltage error of the main circuit devices and the magnetic flux observer of a new system.
  • Page 17 1.1 Features Improved durability in overload operation Enhancement for extending the current overload durability time of the FRENIC-MEGA longer than that of the Fuji conventional inverters allows the FRENIC-MEGA to run the motor with shorter acceleration/deceleration time. This improves the operation efficiency of machinery such as cutting machines or carrier machines.
  • Page 18 Accommodating various applications Convenient functions for operations at the specified speed Pulse train input speed command supported as standard The FRENIC-MEGA can issue a speed command with the pulse train input (single-phase pulse train with sign). (Maximum pulse input: 100 kHz) Ratio operation The ratio operation is convenient for synchronous control of two or more carrier machines in a multiline conveyor system.
  • Page 19 1.1 Features Optimum function for preventing an object from slipping down The reliability of the brake signal was increased for uses such as vertical carrier machines. Conventionally, the current value and the frequency have been monitored when the brake signal is output. By adding a torque value to these two values, the brake timing can be adjusted more easily.
  • Page 20 More functions are available to meet various requirements (1) Analog input: Two terminals for voltage input with polarity and one terminal for current input (2) Slow flowrate level stop function (Pressurized operation is possible before stop of slow flowrate operation.) (3) Non-linear V/f pattern at 3 points (4) Mock alarm output function (5) Selection of up to the 4th motor...
  • Page 21 1.1 Features Various models to meet customer needs Available model variations 1. Standard inverter 2. Inverter with built-in DC reactor (DCR) Reduces harmonics and improves power factor. Available for models rated from 7.5 HP (LD) to 100 HP (LD).
  • Page 22 Inverters supporting synchronous motors (Available soon) 1. Highly-efficient operation for energy saving Driving a synchronous motor(s) with the FRENIC-MEGA equipped with our distinctive energy saving control provides higher energy saving effect than conventional inverter operations of induction motors. 2. Compact, light-weight body for space saving Using advanced, optimum magnetic field analysis technology, thermal analysis technology, and applied analysis technology has attained more compact, light-weight body.
  • Page 23 1.1 Features Supports for simple maintenance The optional remote keypad equipped with a USB port allows use of an inverter support loader "FRENIC Loader" for easy information control! Improved working efficiency at the manufacturing site - A variety of data about the inverter can be saved in the keypad memory so that you can check the information in any place.
  • Page 24 Example of use at the manufacturing site 1-10...
  • Page 25 1.1 Features Network connectivity Connectivity to the various FA networks with the following option cards - SX-bus communications card - T-Link communications card - PROFIBUS-DP communications card - DeviceNet communications card - CANopen communications card - CC-Link communications card - Ethernet communications card RS-485 communication possible as standard (on the terminal block) Besides the port (RJ-45 connector) shared with the keypad, an RS-485 terminal is provided as standard.
  • Page 26 Prolonged service life and improved life judgment function Designed life 10 years For the various consumable parts inside the inverter, their designed lives have been extended to 10 years, which also extended the equipment maintenance cycles. Consumable part Designed life Main circuit capacitor 10 years Electrolytic capacitor on PCB...
  • Page 27 1.1 Features Consideration for environment Enhanced resistance to the environmental impacts Resistance to the environmental impact has been enhanced compared with the conventional inverter. (1) Enhanced durability of the cooling fan operated under the environmental impact (2) Adoption of copper bars plated with nickel or tin In FRENIC-MEGA, resistance to the environmental impact has been increased compared with the conventional model.
  • Page 28 Global compliance Compliance with global standards SINK/SOURCE switching Wide input voltage range Multilingual display on the multi-function keypad (Japanese, English, German, French, Spanish, Italian, Chinese, and Korean) 1-14...

  • Page 29: Control System

    1.2 Control System 1.2 Control System 1.2.1 Theory of inverter As shown in Figure 1.1, the converter section converts the input commercial power to DC power by means of a full-wave rectifier, which charges the DC link bus capacitor (reservoir capacitor). The inverter section modulates the electric energy charged in the DC link bus capacitor by Pulse Width Modulation (PWM) according to the control circuit signals and feeds the output to the motor.
  • Page 30 The voltage applied to the motor has a waveform modulated by the carrier frequency from the dynamic torque vector flux controller that estimates the optimal PWM signal monitoring the inverter output current feedback, as shown on the left-hand side ("PWM voltage waveform") of Figure 1.2. The voltage consists of alternating cycles of positive and negative pulse trains synchronizing with the inverter’s output frequency.

  • Page 31: Motor Drive Controls

    1.2 Control System 1.2.2 Motor drive controls The FRENIC-MEGA supports the following motor drive controls. Drive Basic Speed Drive control control Speed control Other restrictions control feedback class V/f control ― Frequency control with slip compensation inactive ― Disable Dynamic torque vector control Frequency control V/f control with slip compensation...

  • Page 32: External View And Terminal Blocks

    1.3 External View and Terminal Blocks (1) External views Figure 1.3 FRN020G1S-2U Figure 1.4 FRN050G1S-4U 1-18...
  • Page 33 1.3 External View and Terminal Blocks (2) Terminal block location (a) FRN020G1S-2U (b) FRN050G1S-2U Figure 1.5 Terminal Blocks and Keypad Enclosure Location (a) FRN001G1S-2U (b) FRN050G1S-2U Figure 1.6 Enlarged View of the Terminal Blocks Refer to Chapter 2 "SPECIFICATIONS" for details on terminal functions, arrangement and connection and to Chapter 4, Section 4.2.1 "Recommended wires"...

  • Page 34: Recommended Configuration

    1.4 Recommended Configuration To control a motor with an inverter correctly, you should consider the rated capacity of both the motor and the inverter and ensure that the combination matches the specifications of the machine or system to be used. Refer to Chapter 3 "SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES"...
  • Page 35 Chapter 2 SPECIFICATIONS This chapter describes specifications of the output ratings, control system, and terminal functions for the FRENIC-MEGA series of inverters. It also provides descriptions of the operating and storage environment, precautions for using inverters, external dimensions, examples of basic connection diagrams, and details of the protective functions.
  • Page 37 2.1 Standard Model 1 (Standard Inverter) Standard Model 1 (Standard Inverter) 2.1.1 Three-phase 230 V series LD (Low Duty)-mode inverters for light load Item Specifications Type (FRN_ _ _G1S-2U) Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Three-phase 200 to 230 V Rated voltage (V) *3 Three-phase 200 to 240 V (with AVR function) (with AVR function)
  • Page 38 HD (High Duty)-mode inverters for heavy load Item Specifications Type (FRN_ _ _G1S-2U) F50 Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Three-phase 200 to 230 V Rated voltage (V) *3 Three-phase 200 to 240 V (with AVR function) (with AVR function) Rated current (A) Overload capability...
  • Page 39 2.1 Standard Model 1 (Standard Inverter) 2.1.2 Three-phase 460 V series LD (Low Duty)-mode inverters for light load (0.5 to 100 HP) Item Specifications Type (FRN_ _ _G1S-4U) Nominal applied motor (HP) (Output rating) Rated capacity (kVA) 13.1 18.3 Rated voltage (V) *3 Three-phase 380 to 480 V (with AVR function) Rated current (A) 13.5...
  • Page 40 (125 to 1000 HP) Item Specifications Type (FRN_ _ _G1S-4U) 1000 Nominal applied motor (HP) 1000 (Output rating) Rated capacity (kVA) 1092 Rated voltage (V) *3 Three-phase 380 to 480 V (with AVR function) Rated current (A) 1170 1370 Overload capability 120%-1 min 380 to 440 V, 50 Hz Voltage, frequency...
  • Page 41 2.1 Standard Model 1 (Standard Inverter) MD (Medium Duty)-mode inverters for medium load (150 to 700 HP) Item Specifications Type (FRN_ _ _G1S-4U) 150 Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Rated voltage (V) *3 Three-phase 380 to 480 V (with AVR function) Rated current (A) Overload capability 150%-1 min...
  • Page 42 HD (High Duty)-mode inverters for heavy load (0.5 to 75 HP) Item Specifications Type (FRN_ _ _G1S-4U) Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Rated voltage (V) *3 Three-phase 380 to 480 V (with AVR function) Rated current (A) 13.5 13.5 18.5...
  • Page 43 2.1 Standard Model 1 (Standard Inverter) (100 to 900 HP) Item Specifications Type (FRN_ _ _G1S-4U) 125 1000 Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Rated voltage (V) *3 Three-phase 380 to 480 V (with AVR function) Rated current (A) 1170 Overload capability 150%-1 min，200%-3.0 s...

  • Page 44: Standard Model 2 (Inverter With Built-In Dc Reactor)

    Standard Model 2 (Inverter with built-in DC reactor) 2.2.1 Three-phase 230 V series LD (Low Duty)-mode inverters for light load Item Specifications Type (FRN_ _ _G1H-2U) Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Three-phase 200 to 230 V Rated voltage (V) *3 Three-phase 200 to 240 V (with AVR function) (with AVR function)
  • Page 45 2.2 Standard Model 2 (Inverter with built-in DC reactor) HD (High Duty)-mode inverters for heavy load Item Specifications Type (FRN_ _ _G1H-2U) Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Three-phase 200 to 230 V Rated voltage (V) *3 Three-phase 200 to 240 V (with AVR function) (with AVR function) Rated current (A)

  • Page 46: Three-Phase 460 V Series

    2.2.2 Three-phase 460 V series LD (Low Duty)-mode inverters for light load Item Specifications Type (FRN_ _ _G1H-4U) Nominal applied motor (HP) (Output rating) Rated capacity (kVA) 13.1 18.3 Rated voltage (V) *3 Three-phase 380 to 480 V (with AVR function) Rated current (A) 13.5 16.5...
  • Page 47 2.2 Standard Model 2 (Inverter with built-in DC reactor) HD (High Duty)-mode inverters for heavy load Item Specifications Type (FRN_ _ _G1H-4U) Nominal applied motor (HP) (Output rating) Rated capacity (kVA) Rated voltage (V) *3 Three-phase 380 to 480 V (with AVR function) Rated current (A) 13.5 13.5...

  • Page 48: Common Specifications

    Common Specifications Item Explanation Remarks 25 to 500 Hz variable (Up to 120 Hz for LD/MD-mode inverters) Maximum (Up to 120 Hz under vector control without speed sensor) frequency (Up to 200 Hz under V/f control with speed sensor or vector control with speed sensor) Base frequency 25 to 500 Hz variable (in conjunction with the maximum frequency) 0.1 to 60.0 Hz variable...
  • Page 49 2.3 Common Specifications • Possible to set output voltage at base frequency and at maximum output frequency (80 to 240 V). 230 V • The AVR control can be turned ON or OFF. series • Non-linear V/f setting (3 points): Free voltage (0 to 240 V) and frequency (0 to 500 Hz) can be set.
  • Page 50 Setting range: 0.00 to 6000 s Switching: The four types of acceleration/deceleration time can be set or selected individually (switchable during operation). Acceleration/deceleration pattern: Linear acceleration/deceleration, S-shape acceleration/deceleration (weak, free (strong)), curvilinear acceleration/deceleration (acceleration/deceleration max. capacity of constant output) Acceleration/ Acceleration/deceleration pattern: Linear acceleration/deceleration, S-shape deceleration time acceleration/deceleration (weak, free, (strong)), curvilinear acceleration/deceleration...
  • Page 51 2.3 Common Specifications • PID processor for process control/dancer control • Normal operation/inverse operation • Low liquid level stop function (pressurized operation possible before low liquid level stop) • PID command: Keypad, analog input (from terminals [12], [C1] and [V2]), RS-485 communication PID control •...
  • Page 52 • Analog torque command input Torque control • Speed limit function is provided to prevent the motor from becoming out of control. Rotational direction Select either of reverse or forward rotation prevention. control Dew condensation When the motor is stopped, current is automatically supplied to the motor to keep the motor prevention warm and avoid condensation.
  • Page 53 2.3 Common Specifications Stop the inverter output detecting excess cooling fan temperature in case of a cooling fan fault or overload Stop the inverter output detecting a fault of inner agitating fan. (230 V 75 HP, 460 V 125 HP or above) Overheat protection Stop the inverter output detecting inner temperature of the inverter unit for a cooling fan fault...
  • Page 54 Stop the inverter output when tuning failure, interruption, or any fault as a result of tuning is Tuning error detected during tuning for motor constant. RS-485 When the connection port of the keypad connected via RS-485 communication port to detect a communications error communication error, the inverter is stopped and displays an error.
  • Page 55 2.3 Common Specifications Shall be free from corrosive gases, flammable gases, oil mist, dusts, and direct sunlight. Installation location (Pollution degree 2 (IEC60664-1)). Indoor use only. Surrounding -10 to +50°C (14 to 122 F) temperature (-10 to +40°C (14 to 104 F) when installed side-by-side without clearance (40 HP or below)) Relative humidity 5 to 95% RH (without condensation) Altitude...

  • Page 56: Terminal Specifications

    Terminal Specifications 2.4.1 Terminal functions Main circuit and analog input terminals Symbol Name Functions L1/R, Main circuit Connect the three-phase input power lines. L2/S, power inputs L3/T U, V, W Inverter Connect a three-phase motor. outputs R0, T0 Auxiliary Connect AC power lines. power input for the control circuit...
  • Page 57 2.4 Terminal Specifications Symbol Name Functions [C1] Analog (1) The frequency is commanded according to the external current input. setting • 4 to 20 mA DC/0 to 100% (Normal operation) current input • 20 to 4 mA DC/0 to 100 % (Inverse operation) (2) In addition to frequency setting, PID command, PID feedback signal, auxiliary frequency command setting, ratio setting, torque limiter level setting, or analog input monitor can be assigned to this terminal.
  • Page 58 Symbol Name Functions - When the inverter is connected to an external device outputting the analog signal, the external device may malfunction due to electric noise generated by the inverter. If this happens, according to the circumstances, connect a ferrite core (a toroidal core or equivalent) to the device outputting the analog signal or connect a capacitor having the good cut-off characteristics for high frequency between control signal wires as shown in Figure 2.3.
  • Page 59 2.4 Terminal Specifications Symbol Name Functions [EN] Enable input (1) This terminal has the Safe Torque Off (STO) function that is compliant with EN954-1, Category 3. It allows the hardware circuit to stop the inverter's output transistors and coast the motor to a stop. (2) This terminal is exclusively used for the source mode input.
  • Page 60 Symbol Name Functions Using a programmable logic controller (PLC) to turn [X1] to [X7], [FWD], and [REV] ON or Figure 2.6 shows two examples of a circuit that uses a programmable logic controller (PLC) to turn control signal inputs [X1] to [X7], [FWD], and [REV] ON or OFF. In circuit (a), the slide switch SW1 is turned to SINK, whereas in circuit (b) it is turned to SOURCE.
  • Page 61 2.4 Terminal Specifications Symbol Name Functions [FM1] Analog Both terminals output monitor signals for analog DC voltage (0 to +10 V) or analog [FM2] monitor DC current (+4 to +20 mA). The output form (VO/IO) for each of [FM1] and [FM2] can be switched with the slide switches on the control PCB and the function codes, as listed below.
  • Page 62 Symbol Name Functions [CMY] Transistor Common terminal for transistor output signals output This terminal is electrically isolated from terminals [CM] and [11]s. common Connecting programmable logic controller (PLC) to terminal [Y1], [Y2], [Y3] or [Y4] Figure 2.8 shows two examples of circuit connection between the transistor output of the inverter’s control circuit and a PLC.
  • Page 63 2.4 Terminal Specifications Symbol Name Functions [DX+]/ A communications port transmits data through the RS-485 multipoint protocol RS-485 [DX-]/ between the inverter and a computer or other equipment such as a PLC. communications [SD] port 2 (For setting of the terminating resistor, refer to Section 2.4.2 "Setting up the slide (Terminals on switches.") control PCB)
  • Page 64 Wiring for control circuit terminals For FRN125G1S-2U, FRN150G1S-2U and FRN250G1S-4U to FRN1000G1S-4U (1) As shown in Figure 2.10, route the control circuit wires along the left side panel to the outside of the inverter. (2) Secure those wires to the wiring support, using a cable tie (e.g., Insulok) with 0.15 inch (3.8 mm) or less in width and 0.059 inch (1.5 mm) or less in thickness.

  • Page 65: Setting Up The Slide Switches

    2.4 Terminal Specifications 2.4.2 Setting up the slide switches Before changing the switches or touching the control circuit terminal symbol plate, turn OFF the power and wait at least five minutes for inverters of 40 HP or below, or at least ten minutes for those of 50 HP or above.
  • Page 66 Figure 2.11 shows the location of slide switches on the control PCB for the input/output terminal configuration. Switch Configuration and Factory Defaults SW4/SW6 VO1/VO2 Factory default SINK SOURCE IO1/IO2 PTC/NTC Figure 2.11 Location of the Slide Switches on the Control PCB To move a switch slider, use a tool with a narrow tip (e.g., a tip of tweezers).

  • Page 67: Terminal Arrangement And Screw Specifications

    2.4 Terminal Specifications 2.4.3 Terminal arrangement and screw specifications 2.4.3.1 Main circuit terminals The tables and figures given below show the screw specifications and wire sizes. Note that the terminal arrangements differ depending on the inverter types. In each of the figures, two grounding terminals ( G) are not exclusive to the power supply wiring (primary circuit) or motor wiring (secondary circuit).
  • Page 68 Unit: inch (mm) Refer to Section 2.4.4 (9). 2-32...
  • Page 69 2.4 Terminal Specifications Table 2.2 (2) Recommended Wire Sizes Inverter type Recommended wire size AWG (mm Power Braking supply L1/R, L2/S, Grounding LD mode MD mode HD mode U, V, W resistor voltage L3/T [ G] [P1, P(+)] [P(+), DB] FRNF50G1S-2U FRNF50G1S-2U 14 (2.1)

  • Page 70: Control Circuit Terminals (Common To All Inverter Types)

    Recommended wire size Terminals common to all inverters Remarks AWG (mm Auxiliary control power input terminals 2 HP or above [R0] and [T0] 14 (2.1) Auxiliary fan power input terminals 230 V series with 60 HP or above and [R1] and [T1] 460 V series with 125 HP or above 2.4.3.2 Control circuit terminals (common to all inverter types)
  • Page 71 2.4 Terminal Specifications (7) Use the wiring guide to separate wiring. For inverters of 5 HP or below, the wiring guide separates the main circuit wires and the control circuit wires. For those of 7.5 to 40 HP, it separates the upper and lower main circuit wires, and control circuit wires.
  • Page 72 (9) For inverters of 900 and 1000 HP, two L2/S input terminals are arranged vertically to the terminal block. When connecting wires to these terminals, use the bolts, washers and nuts that come with the inverter, as shown below. • When wiring the inverter to the power source, insert a recommended molded case circuit breaker (MCCB) or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection) in the path of each pair of power lines to inverters.

  • Page 73: Operating Environment And Storage Environment

    2.5 Operating Environment and Storage Environment Operating Environment and Storage Environment 2.5.1 Operating environment Install the inverter in an environment that satisfies the requirements listed in Table 2.3. Table 2.3 Environmental Requirements Item Specifications Site location Indoors Surrounding/ambient -10 to +50 C (14 to 122 F) (Note 1) temperature Relative humidity...

  • Page 74: Storage Environment

    2.5.2 Storage environment 2.5.2.1 Temporary storage Store the inverter in an environment that satisfies the requirements listed below. Table 2.5 Storage and Transport Environments Item Specifications Storage -25 to +70 C (-13 to +158 F) temperature Places not subjected to abrupt temperature changes or condensation or freezing Relative 5 to 95%...

  • Page 75: Precautions For Using Inverters

    Install the inverter in an environment that satisfies the requirements listed in Table 2.3 in Section 2.5.1. Fuji Electric strongly recommends installing inverters in a panel for safety reasons, in particular, when installing the ones whose enclosure rating is IP00.

  • Page 76: Wiring Precautions

    Environments Possible problems Sample measures Applications Vibration or shock If a large vibration or shock - Insert shock-absorbing materials Installation of an inverter exceeding the exceeding the specified level between the mounting base of panel on a carrier or specified level is applied to the inverter, for the inverter and the panel for safe self-propelled machine.
  • Page 77 2.6 Precautions for Using Inverters (5) When an output circuit filter is inserted in the secondary circuit or the wiring between the inverter and the motor is long, a voltage loss occurs due to reactance of the filter or wiring so that the insufficient voltage may cause output current oscillation or a lack of motor output torque.
  • Page 78 (5) Molded case circuit breaker (MCCB) or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) Install a recommended MCCB or RCD/ELCB (with overcurrent protection) in the primary circuit of the inverter to protect the wiring. Since using an MCCB or RCD/ELCB with a lager capacity than recommended ones breaks the protective coordination of the power supply system, be sure to select recommended ones.
  • Page 79 2.6 Precautions for Using Inverters Noise reduction If noise generated from the inverter affects other devices, or that generated from peripheral equipment causes the inverter to malfunction, follow the basic measures outlined below. (1) If noise generated from the inverter affects the other devices through power wires or grounding wires: - Isolate the grounding terminals of the inverter from those of the other devices.

  • Page 80: Precautions In Running Inverters

    2.6.2 Precautions in running inverters Precautions for running inverters to drive motors or motor-driven machinery are described below. Motor temperature When an inverter is used to run a general-purpose motor, the motor temperature becomes higher than when it is operated with a commercial power supply. In the low-speed range, the motor cooling effect will be weakened, so decrease the output torque of the motor when running the inverter in the low-speed range.
  • Page 81 If the power transmission mechanism uses an oil-lubricated gearbox or speed changer/reducer, then continuous operation at low speed may cause poor lubrication. Avoid such operation. Synchronous motors It is necessary to take special measures suitable for this motor type. Contact your Fuji Electric representative for details. Single-phase motors Single-phase motors are not suitable for inverter-driven variable speed operation.

  • Page 82: External Dimensions

    External Dimensions 2.7.1 Standard Inverter The diagrams below show external dimensions of the FRENIC-MEGA series of inverters according to the inverter capacity. (Three-phase 230/460 V series) Unit: inch [mm] FRNF50G1S-2U/4U FRN001G1S-2U/4U 2-46...
  • Page 83 2.7 External Dimensions Unit: inch [mm] FRN002G1S-2U/4U, FRN003G1S-2U/4U, FRN005G1S-2U/4U FRN007G1S-2U/4U, FRN010G1S-2U/4U, FRN015G1S-2U/4U, FRN020G1S-2U/4U 2-47...
  • Page 84 Unit: inch [mm] FRN025G1S-2U/4U, FRN030G1S-2U/4U, FRN040G1S-2U/4U FRN050G1S-2U/4U, FRN060G1S-4U 2-48...
  • Page 85 2.7 External Dimensions Unit: inch [mm] FRN060G1S-2U, FRN075G1S-4U FRN100G1S-4U 2-49...
  • Page 86 Unit: inch [mm] FRN075G1S-2U, FRN100G1S-2U, FRN125G1S-4U FRN125G1S-2U 2-50...
  • Page 87 2.7 External Dimensions Unit: inch [mm] FRN150G1S-2U FRN150G1S-4U, FRN200G1S-4U, 2-51...
  • Page 88 Unit: inch [mm] FRN250G1S-4U, FRN300G1S-4U FRN350G1S-4U, FRN450G1S-4U 2-52...
  • Page 89 2.7 External Dimensions Unit: inch [mm] FRN500G1S-4U, FRN600G1S-4U FRN700G1S-4U, FRN800G1S-4U 2-53...
  • Page 90 Unit: inch [mm] FRN900G1S-4U, FRN1000G1S-4U 2-54...

  • Page 91: Inverter With Built-In Dc Reactor

    2.7 External Dimensions 2.7.2 Inverter with built-in DC reactor Unit: inch [mm] FRN007G1H-2U/4U, FRN010G1H-2U/4U, FRN015G1H-2U/4U, FRN020G1H-2U/4U FRN025G1H-2U/4U, FRN030G1H-2U/4U, FRN040G1H-2U/4U 2-55...
  • Page 92 Unit: inch [mm] FRN050G1H-2U/4U, FRN060G1H-4U FRN060G1H-2U, FRN075G1H-4U 2-56...
  • Page 93 2.7 External Dimensions Unit: inch [mm] FRN075G1H-2U, FRN100G1H-2U FRN100G1H-4U 2-57...

  • Page 94: Keypad (Tp-G1W-J1)

    2.7.3 Keypad (TP-G1W-J1) Unit: inch (mm) Drill four screw holes and cut a square hole in a panel as specified below. Location of Screw Holes in Panel (viewed from back) Dimensions of Panel Cutting 2-58...

  • Page 95: Connection Diagrams

    2.8 Connection Diagrams Connection Diagrams This section shows connection diagrams with the Enable input function used. 2.8.1 Running a standard motor SINK mode input by factory default 2-59...
  • Page 96 Install a recommended molded case circuit breaker (MCCB) or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection function) in the primary circuit of the inverter to protect wiring. Ensure that the circuit breaker capacity is equivalent to or lower than the recommended capacity.

  • Page 97: Running A Fuji Motor Exclusively Designed For Vector Control

    2.8 Connection Diagrams 2.8.2 Running a Fuji motor exclusively designed for vector control 2-61...
  • Page 98 Install a recommended molded case circuit breaker (MCCB) or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection function) in the primary circuit of the inverter to protect wiring. Ensure that the circuit breaker capacity is equivalent to or lower than the recommended capacity.

  • Page 99: Protective Functions

    2.9 Protective Functions Protective Functions The table below lists the name of the protective functions, description, alarm codes on the LED monitor, and presence of alarm output at terminals [30A/B/C]. If an alarm code appears on the LED monitor, remove the cause of activation of the alarm function referring to Chapter 9 "TROUBLESHOOTING." Alarm output Name Description...
  • Page 100 Alarm output Name Description monitor [30A/B/C] displays (Note) - Stops the inverter output upon detecting excess heat sink Overheat temperature in case of cooling fan failure or overload. protection - Detects a failure of the internal air circulation DC fan and stops the inverter (For models of 75 HP in 230 V series and 125 HP or above in 460 V series )
  • Page 101 2.9 Protective Functions Alarm output Name Description monitor [30A/B/C] displays (Note) Electronic In the following cases, the inverter stops running the motor to Yes* thermal protect the motor in accordance with the electronic thermal overload overload protection setting. - Protects general-purpose motors over the entire frequency range (F10 = 1.) - Protects inverter motors over the entire frequency range (F10 = 2.)
  • Page 102 Alarm output Name Description monitor [30A/B/C] displays (Note) Operation STOP Pressing the key on the keypad forces the inverter to decelerate and stop the motor even if the inverter is protection running by any run commands given via the terminals or priority communications (link operation).
  • Page 103 2.9 Protective Functions Alarm output Name Description monitor [30A/B/C] displays (Note) Alarm relay The inverter outputs a relay contact signal when the inverter issues — output an alarm and stops the inverter output. (for any fault) < Alarm reset > The alarm stop state is reset by pressing the key or by the digital input signal RST.
  • Page 105 Chapter 3 SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES This chapter provides you with information about the inverter output torque characteristics, selection procedure, and equations for calculating capacities to help you select optimal motor and inverter models. It also helps you select braking resistors, inverter mode (LD, MD, or HD), and motor drive control.

  • Page 107: Selecting Motors And Inverters

    3.2 Selecting a Braking Resistor Selecting Motors and Inverters When selecting a general-purpose inverter, first select a motor and then inverter as follows: (1) Key point for selecting a motor: Determine what kind of machinery is to be used, calculate its moment of inertia, and then select the appropriate motor capacity.
  • Page 108 Figure 3.2 Output Torque Characteristics (Base frequency: 60 Hz) Continuous allowable driving torque Standard motor (Curve (a1) in Figures 3.1 and 3.2) Curve (a1) shows the torque characteristic that can be obtained in the range of the inverter continuous rated current, where the standard motor's cooling characteristic is taken into consideration. When the motor runs at the base frequency of 60 Hz, 100 % output torque can be obtained;...
  • Page 109 3.2 Selecting a Braking Resistor Starting torque (around the output frequency 0 Hz in Figures 3.1 and 3.2) The maximum torque in a short time applies to the starting torque as it is. Braking torque (Curves (d), (e), and (f) in Figures 3.1 and 3.2) In braking the motor, kinetic energy is converted to electrical energy and regenerated to the DC link bus capacitor (reservoir capacitor) of the inverter.

  • Page 110: Selection Procedure

    3.1.2 Selection procedure Figure 3.3 shows the general selection procedure for optimal inverters. Items numbered (1) through (5) are described on the following pages. You may easily select inverter capacity if there are no restrictions on acceleration and deceleration times. If "there are any restrictions on acceleration or deceleration time"...
  • Page 111 3.2 Selecting a Braking Resistor (1) Calculating the load torque during constant speed running (For detailed calculation, refer to Section 3.1.3.1) It is essential to calculate the load torque during constant speed running for all loads. First calculate the load torque of the motor during constant speed running and then select a tentative capacity so that the continuous rated torque of the motor during constant speed running becomes higher than the load torque.
  • Page 112 (3) Deceleration time (For detailed calculation, refer to Section 3.1.3.2) To calculate the deceleration time, check the motor deceleration torque characteristics for the whole range of speed in the same way as for the acceleration time. 1) Calculate the moment of inertia for the load and motor Same as for the acceleration time.

  • Page 113: Equations For Selections

    3.2 Selecting a Braking Resistor 3.1.3 Equations for selections Expressions given in this section are based on SI units (International System of Units). For other units, make a conversion, referring to the following. (inch) ÷ 0.03937 = (mm) (inch) ÷ 39.37 = (m) (ft) ÷3.2808 = (m) (N) = (kg·m/s (lbs) ÷...

  • Page 114: 2 ] Obtaining The Required Force F

    [ 2 ] Obtaining the required force F Moving a load horizontally A simplified mechanical configuration is assumed as shown in Figure 3.7. If the mass of the carrier table is (kg), the load is W (kg), and the friction coefficient of the ball screw is , then the friction force F (N) is expressed as follows, which is equal to a required force for driving the load: (3.3) where, g is the gravity acceleration ( 9.8 (m/s...
  • Page 115 3.2 Selecting a Braking Resistor Inclined lift load Although the mechanical configuration of an inclined lift load is similar to that of a vertical lift load, unignorable friction force in the inclined lift makes a difference; in an inclined lift load, there is a distinct difference between the expression to calculate the lift force F (N) for lifting up and that for lifting down.

  • Page 116: Acceleration And Deceleration Time Calculation

    3.1.3.2 Acceleration and deceleration time calculation When an object whose moment of inertia is J (kg·m ) rotates at the speed N (min ), it has the following kinetic energy: (3.9) To accelerate the above rotational object, the kinetic energy will be increased; to decelerate the object, the kinetic energy must be discharged.
  • Page 117 3.2 Selecting a Braking Resistor Table 3.1 Moment of Inertia of Various Rotating Bodies Mass: W (kg) Mass: W (kg) Shape Shape Moment of inertia: Moment of inertia: J (kg·m J (kg·m Hollow cylinder Sphere Cone Rectangular prism Square cone (Pyramid, rectangular base) Triangular prism Tetrahedron with an...

  • Page 118: 2 ] Calculation Of The Acceleration Time

    For a load running horizontally Assume a carrier table driven by a motor as shown in Figure 3.7. If the table speed (m/s) when the motor speed is N (min ), then an equivalent distance from the shaft is equal to 60· / (2 ·N ) (m).

  • Page 119: 3 ] Calculation Of The Deceleration Time

    3.2 Selecting a Braking Resistor [ 3 ] Calculation of the deceleration time In a load system shown in Figure 3.11, the time needed to stop the motor rotating at a speed of N (min is calculated with the following equation: (3.16) where, : Motor shaft moment of inertia (kg·m...
  • Page 120 [4-1] Calculating non-linear acceleration time The expression (3.17) gives an acceleration time Δt within a ΔN speed thread. / η 2π ΔN Δt (3.17) τ - τ / η Before proceeding this calculation, obtain the motor shaft moment of inertia J , the load shaft moment of inertia converted to motor shaft J , maximum load torque converted to motor shaft τ...

  • Page 121: Heat Energy Calculation Of Braking Resistor

    3.2 Selecting a Braking Resistor 3.1.3.3 Heat energy calculation of braking resistor If the inverter brakes the motor, the kinetic energy of mechanical system is converted to electric energy to be regenerated into the inverter circuit. This regenerative energy is often consumed in so-called braking resistors as heat.

  • Page 122: Calculating The Rms Rating Of The Motor

    3.1.3.4 Calculating the RMS rating of the motor In case of the load which is repeatedly and very frequently driven by a motor, the motor current fluctuates largely and enters the short-time rating range of the motor repeatedly. Therefore, you have to review the allowable thermal rating of the motor.

  • Page 123: Selecting A Braking Resistor

    3.2 Selecting a Braking Resistor Selecting a Braking Resistor 3.2.1 Selection procedure Depending on the cyclic period, the following requirements must be satisfied. If the cyclic period is 100 s or less: Requirements 1) and 3) below If the cyclic period exceeds 100 s: Requirements 1) and 2) below 1) The maximum braking torque should not exceed values listed in Tables 4.6 to 4.9 in Chapter 4, Section 4.4.1.1 "Braking resistors (DBRs) and braking units."...

  • Page 124: Selecting An Inverter Drive Mode (Ld/Md/Hd)

    Selecting an Inverter Drive Mode (LD/MD/HD) Precaution in making the selection 3.3.1 The FRENIC-MEGA series of inverters is applicable to three ratings--low duty (LD) for light load applications, medium duty (MD) for medium load ones, and high duty (HD) for heavy load ones. The MD mode is available for inverters of 150 to 800 HP with three-phase 460 V input.

  • Page 125: Guideline For Selecting Inverter Drive Mode And Capacity

    3.3 Selecting an Inverter Drive Mode (LD/MD/HD) 3.3.2 Guideline for selecting inverter drive mode and capacity Table 3.2 lists the differences between LD, MD, and HD modes. Note: The MD mode is available for inverters of 150 to 800 HP with three-phase 460 V input. Note: For inverters of 7.5 HP and smaller, when LD mode is selected, the HD mode specification applies.

  • Page 126: Selecting A Motor Drive Control

    Selecting a Motor Drive Control 3.4.1 Features of motor drive controls The FRENIC-MEGA supports the following motor drive controls. This section shows their basic configurations and describes their features. Drive Basic Speed Drive control control Speed control Other restrictions control feedback class V/f control...
  • Page 127 3.4 Selecting a Motor Drive Control V/f control with slip compensation inactive <Main circuit> Converter Inverter Ｍ <Control block> |V *| pattern Three- Accelerator/ processor phase decelerator voltage processor processor Frequency command Figure 3.15 Schematic Block Diagram of V/f Control with Slip Compensation Inactive As shown in the above configuration, the inverter does not receive any speed information feedback from the target machinery being controlled and it controls the load shaft speed only with a frequency command given by the frequency setting device (open-loop control).
  • Page 128 The FRENIC-MEGA features the dynamic torque vector controller with the flux estimator, which is always correcting the magnetic flux phase while monitoring the inverter output current as the feedback. This feature allows the inverter to always apply the drive power with an optimal voltage and current and consequently respond to quick load variation or speed change.
  • Page 129 3.4 Selecting a Motor Drive Control Vector control without speed sensor <Main circuit> Converter Inverter <Control block> Current analyzer Speed regulator Current analyzer Speed command Speed estimator Figure 3.18 Schematic Block Diagram of Vector Control without Speed Sensor This control estimates the motor speed based on the inverter's output voltage and current to use the estimated speed for speed control.
  • Page 130 Vector control with speed sensor <Main circuit> Converter Inverter Speed sensor <Control block> ＋ Current analyzer － Speed regulator Current analyzer Speed command PG interface card Figure 3.19 Schematic Block Diagram of Vector Control with Speed Sensor As shown in the above configuration, the inverter is equipped with an optional PG (Pulse Generator) interface card and receives the feedback signals from the PG to detect the motor rotational position and speed.

  • Page 131: Selecting A Motor Drive Control By Purpose

    3.4 Selecting a Motor Drive Control 3.4.2 Selecting a Motor Drive Control by Purpose Listed below is a general guide for selecting a motor drive control by purpose. Use this guide just for reference. In individual cases, selection should be made carefully after a technical consultation regarding the detailed specifications of your system.
  • Page 132 Table 3.3 Motor Drive Control by Purpose (Continued) Drive control abbreviation: "V/f" (V/f control), "Torque vector" (Dynamic torque vector control), "w/o PG" (Vector control without speed sensor), "w/ PG" (Vector control with speed sensor) Drive control Type of Applications Segment Torque industry w/o PG w/ PG...

  • Page 133: Selecting Peripheral Equipment

    Chapter 4 SELECTING PERIPHERAL EQUIPMENT This chapter describes how to use a range of peripheral equipment and options, FRENIC-MEGA's configuration with them, and requirements and precautions for selecting wires and crimp terminals. Contents 4.1 Configuring the FRENIC-MEGA ....................... 4-1 4.2 Selecting Wires and Crimp Terminals ......................4-2 4.2.1 Recommended wires ...........................
  • Page 134 [ 3 ] Specifications ..........................4-49 [ 4 ] Change settings ..........................4-50 4.4.2 Options for operation and communication ..................4-51 4.4.2.1 External frequency command potentiometer ................4-51 4.4.2.2 Extension cable for remote operation ..................4-53 4.4.2.3 Inverter support loader software ....................4-54 4.4.2.4 PG interface card (OPC-G1-PG) ....................

  • Page 135: Configuring The Frenic-Mega

    4.1 Configuring the FRENIC-MEGA Configuring the FRENIC-MEGA This section lists the names and features of peripheral equipment and options for the FRENIC-MEGA series of inverters and includes a configuration example for reference. Refer to Figure 4.1 for a quick overview of available options. Figure 4.1 Quick Overview of Options...

  • Page 136: Selecting Wires And Crimp Terminals

    Selecting Wires and Crimp Terminals This section contains information needed to select wires for connecting the inverter to commercial power lines, motor or any of the optional/peripheral equipment. The level of electric noise issued from the inverter or received by the inverter from external sources may vary depending upon wiring and routing. To solve such noise-related problems, refer to Appendix A "Advantageous Use of Inverters (Notes on electrical noise)."...
  • Page 137 50 HP or above: Power supply capacity and power supply impedance which are calculated using values matching the inverter capacity recommended by Fuji Electric Systems. - The input RMS current listed in the above table will vary in inverse proportion to the power supply voltage, such as 200 VAC.
  • Page 138 50 HP or above: Power supply capacity and power supply impedance which are calculated using values matching the inverter capacity recommended by Fuji Electric Systems. - The input RMS current listed in the above table will vary in inverse proportion to the power supply voltage, such as 400 VAC.
  • Page 139 50 HP or above: Power supply capacity and power supply impedance which are calculated using values matching the inverter capacity recommended by Fuji Electric Systems. - The input RMS current listed in the above table will vary in inverse proportion to the power supply voltage, such as 400 VAC.

  • Page 140: Recommended Wires

    4.2.1 Recommended wires Table 4.2 lists the recommended wires according to the internal temperature of your power control panel. Table 4.2 Recommended Wire Sizes LD (Low Duty) mode: Light duty load applications MD (Medium Duty) mode: Medium duty load applications HD (High Duty) mode: Heavy duty load applications Inverter type...
  • Page 141 4.2 Selecting Wires and Crimp Terminals Table 4.2 Recommended Wire Sizes (continued) LD (Low Duty) mode: Light duty load applications MD (Medium Duty) mode: Medium duty load applications HD (High Duty) mode: Heavy duty load applications Inverter type Recommended wire size AWG (mm Auxiliary Auxiliary Power...

  • Page 142: Peripheral Equipment

    Peripheral Equipment 4.3.1 Molded case circuit breaker (MCCB), residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) and magnetic contactor (MC) [ 1 ] Functional overview MCCBs and RCDs/ELCBs* * With overcurrent protection Molded Case Circuit Breakers (MCCBs) are designed to protect the power circuits between the power supply and inverter's main circuit terminals ([L1/R], [L2/S] and [L3/T]) from overload or short-circuit, which in turn prevents secondary accidents caused by the broken inverter.
  • Page 143 4.3 Peripheral Equipment At the output side Insert an MC in the power output side of the inverter in order to: (1) Prevent externally turned-around current from being applied to the inverter power output terminals ([U], [V], and [W]) unexpectedly. An MC should be used, for example, when a circuit that switches the motor driving power supply between the inverter output and commercial power lines is connected to the inverter.

  • Page 144: 2 ] Connection Example And Criteria For Selection Of Circuit Breakers

    [ 2 ] Connection example and criteria for selection of circuit breakers Figure 4.2 shows a connection example for MCCB or RCD/ELCB (with overcurrent protection) and MC in the inverter input circuit. Table 4.3 lists the rated current for the MCCB and corresponding inverter models.
  • Page 145 4.3 Peripheral Equipment Table 4.3 Rated Current of Molded Case Circuit Breaker (MCCB), Residual-Current-Operated Protective Device (RCD)/Earth Leakage Circuit Breaker (ELCB) LD (Low Duty) mode: Light duty load applications HD (High Duty) mode: Heavy duty load applications MCCB or RCD/ELCB Nominal applied Power supply motor...
  • Page 146 Table 4.3 Rated Current of Molded Case Circuit Breaker (MCCB), Residual-Current-Operated Protective Device (RCD)/Earth Leakage Circuit Breaker (ELCB) (continued) LD (Low Duty) mode: Light duty load applications MD (Medium Duty) mode: Medium duty load applications HD (High Duty) mode: Heavy duty load applications Nominal applied MCCB or RCD/ELCB Power supply...
  • Page 147 4.3 Peripheral Equipment - To protect your power systems from secondary accidents caused by the broken inverter, use an MCCB and/or RCD/ELCB with the rated current listed in the above table. Do not use an MCCB or RCD/ELCB with a rating higher than that listed. 4-13...
  • Page 148 Table 4.4 lists the relationship between the rated leakage current sensitivity of RCDs/ELCBs (with overcurrent protection) and wiring length of the inverter output circuits. Note that the sensitivity levels listed in the table are estimated values based on the results obtained by the test setup in the Fuji laboratory where each inverter drives a single motor.

  • Page 149: Surge Killers For L-Load

    Refer to the catalog "Fuji Surge Killers/Absorbers (HS118: Japanese edition only)" for details. These products are available from Fuji Electric Technica Co., Ltd. Note: Do not connect the surge killers in the secondary (output) circuit of the inverter.

  • Page 150: Arresters

    4.3.3 Arresters An arrester suppresses surge currents induced by lightning invaded from the power supply lines. Common use of the grounding wire that is used for electric equipment in the panel, with the arrester, is effective in preventing electronic equipment from damage or malfunctioning caused by such surges. Applicable arrester models are CN23232 for three-phase 230 V series, and CN2324E and CN2324L for three-phase 460 V series.

  • Page 151: Surge Absorbers

    Installed parallel to a coil of an MC, solenoid valve, or L load, a surge absorber absorbs a surge voltage. Applicable surge absorber models are the S2-A-O and S1-B-O. Figure 4.5 shows their external dimensions. The surge absorbers are available from Fuji Electric Technica Co., Ltd. Unit: inch (mm) Figure 4.5 Surge Absorber Dimensions...

  • Page 152: Filtering Capacitors Suppressing Am Radio Band Noises

    Applicable models are NFM25M315KPD1 for 230 V series inverters and NFM60M315KPD for 460 V series. Use one of them no matter what the inverter capacity. Figure 4.6 shows their external dimensions. These products are available from Fuji Electric Technica Co., Ltd. Note: Do not use the capacitor in the inverter secondary (output) line.

  • Page 153: Selecting Options

    4.4 Selecting Options Selecting Options 4.4.1 Peripheral equipment options 4.4.1.1 Braking resistors (DBRs) and braking units [ 1 ] Braking resistors (DBRs) A braking resistor converts regenerative energy generated from deceleration of the motor to heat for consumption. Use of a braking resistor results in improved deceleration performance of the inverter. Refer to Chapter 3, Section 3.2 "Selecting a Braking Resistor."...

  • Page 154: 2 ] Braking Units

    [ 2 ] Braking units For inverters of 50 HP or above, add a braking unit to the braking resistor to upgrade the braking capability of inverters with the following capacity. Figure 4.8 Braking Unit For the specifications and external dimensions of the braking units, refer to [ 3 ] and [ 4 ] in this Section.

  • Page 155: 3 ] Specifications

    4.4 Selecting Options [ 3 ] Specifications Table 4.5 Generated Loss in Braking Unit Model Generated loss (W) BU37-2C BU55-2C BU90-2C BU37-4C BU55-4C BU90-4C BU132-4C BU220-4C *10%ED Table 4.6 Braking Unit and Braking Resistor (Standard Model) for LD-mode Inverters Continuous braking Repetitive braking Option Maximum braking...
  • Page 156 Table 4.7 Braking Unit and Braking Resistor (Standard Model) for MD-mode Inverters Continuous braking Repetitive braking Options Maximum braking Inverter type (100% braking (each cycle is less Nominal torque (%) Power Braking unit Braking resistor torque) than 100 s) applied supply motor 50 Hz 60 Hz Discharging...

  • Page 157: 4 ] External Dimensions

    4.4 Selecting Options [ 4 ] External dimensions Braking resistors, standard models Mass lb (kg) 0.9 (0.4) 1.8 (0.8) 3.1 (1.4) 5.7 (2.6) 6.2 (2.8) 9.5 (4.3) 12 (5.6) 19 (8.4) Figure A 230V series 460V series Figure B * DB220-4C should be used in pairs. The dimension above is for one unit. 4-23...
  • Page 158 Braking units Fan units for braking units Using this option improves the duty cycle [%ED] from 10%ED to 30%ED. 4-24...

  • Page 159: Power Regenerative Pwm Converters, Rhc Series

    4.4 Selecting Options 4.4.1.2 Power regenerative PWM converters, RHC series [ 1 ] Overview 4-25...

  • Page 160: 2 ] Specifications

    [ 2 ] Specifications [2.1] Standard specifications 200 V class series 400 V class series (*1) When the power supply voltage is 200/400 V, 220/440 V, or 230/460 V, the output voltage is approximate 320/640 VDC, 343/686 VDC, 355/710 VDC, respectively. (*2) The 220 to 230 V/50 Hz models are available on request.

  • Page 161: Keypad

    4.4 Selecting Options [2.2] Common specifications Item Specifications Control method AVR constant control with DC ACR minor Running/Stopping Starts rectification when the converter is powered ON after connection. Starts boosting when it receives a run signal (terminals [RUN] and [CM] short-circuited or a run command via the communications link).

  • Page 162: 3 ] Function Specifications

    [ 3 ] Function specifications Terminal functions Symbol Name Functions L1/R, L2/S, Main circuit power Connects with the three-phase input power lines through a dedicated L3/T inputs reactor. P(+), N(-) Converter outputs Connects with the power input terminals P(+) and N(-) on an inverter. Grounding Grounding terminal for the converter's chassis (or casing).
  • Page 163 4.4 Selecting Options Symbol Name Functions Analog output common Common terminal for analog output signal. [73A], [73C] Charging resistor input Control output for the input relay of the external charging resistor (73). relay outputs Communications specifications Item Specifications General communication Monitoring the running information, running status and function code specifications data, and controlling (selecting) the terminals [RUN], [RST] and [X1].
  • Page 164 Function Function Name Name code code Protocol selection Power supply frequency TL transmission format Input power Parallel system Input current in RMS Number of slave stations in parallel system Input voltage in RMS Clear alarm data Run command H15, H16 Power supply current limiter (driving 1/2) Running status H17, H18...
  • Page 165 4.4 Selecting Options monitor Item Description Remarks displays: Charging circuit fault Stops the converter output upon detection of a Condition: 73ANS charging circuit fault, provided that the answerback (Answerback from 73) signal from 73 is enabled. assigned to terminal [X1]. Heat sink overheat Stops the converter output upon detection of a heat sink overheat.
  • Page 166 Required structure and environment Item Required structure, environment and standards Remarks Structure Mounting in a panel or mounting for external cooling Enclosure IP00 Cooling system Forced air cooling Installation Vertical installation Coating color Munsell 5Y3/0.5, eggshell (Same color as our inverter FRENIC 5000VG7S series.) Maintainability Structure designed for easy parts replacement Site location...

  • Page 167: 4 ] Converter Configuration

    4.4 Selecting Options [ 4 ] Converter configuration List of configurators CT mode VT mode (*1) The charging box (CU) contains a combination of a charging resistor (R0) and a fuse (F). If no CU is used, it is necessary to prepare the charging resistor (R0) and fuse (F) at your end.
  • Page 168 Basic connection diagrams RHC7.5-2C to RHC90-2C RHC7.5-4C to RHC220-4C *When a charging box is connected Symbol Part name Boosting reactor Filtering reactor Filtering capacitor Filtering resistor Charging box Magnetic contactor for charging circuit (*1) For the 400 V class power supply, connect a stepdown transformer to limit the voltage of the sequence circuit to 220 V or below. (*2) Be sure to connect the auxiliary power input terminals R0 and T0 of the PWM converter to the main power input lines via B contacts of magnetic contactors of the charging circuit (73 or MC).
  • Page 169 4.4 Selecting Options RHC7.5-2C to RHC90-2C RHC7.5-4C to RHC220-4C Symbol Part name Boosting reactor Filtering reactor Filtering capacitor Filtering resistor Charging resistor Fuse Magnetic contactor for charging circuit (*1) For the 400 V class power supply, connect a stepdown transformer to limit the voltage of the sequence circuit to 220 V or below. (*2) Be sure to connect the auxiliary power input terminals R0 and T0 of the PWM converter to the main power input lines via B contacts of magnetic contactors of the charging circuit (73 or MC).
  • Page 170 RHC280-4C to RHC400-4C Symbol Part name Boosting reactor Filtering reactor Filtering capacitor Filtering resistor Charging resistor Fuse Magnetic contactor for charging circuit Magnetic contactor for power supply Magnetic contactor for filtering circuit (*1) Connect a stepdown transformer to limit the voltage of the sequence circuit to 220 V or below. (*2) Be sure to connect the auxiliary power input terminals R0 and T0 of the PWM converter and the inverter to the main power input lines via B contacts of magnetic contactors of the power supply circuit (52).
  • Page 171 4.4 Selecting Options RHC400-4C in VT mode RHC500-4C and RHC630-4C Symbol Part name Boosting reactor Filtering reactor Filtering capacitor Filtering resistor Charging resistor Fuse Magnetic contactor for charging circuit Magnetic contactor for power supply Magnetic contactor for filtering circuit (*1) Connect a stepdown transformer to limit the voltage of the sequence circuit to 220 V or below. (*2) Be sure to connect the auxiliary power input terminals R0 and T0 of the PWM converter and the inverter to the main power input lines via B contacts of magnetic contactors of the power supply circuit (52).

  • Page 172: 5 ] External Dimensions

    [ 5 ] External dimensions PWM converter < Boosting reactor > 4-38...
  • Page 173 4.4 Selecting Options < Filtering reactor > < Filtering capacitor > 4-39...
  • Page 174 < Filtering resistor > < Charging box > The charging box contains a combination of a charging resistor and a fuse, which is essential in the configuration of the RHC-C series of PWM converters. Using this charging box eases mounting and wiring jobs. Capacity range 200 V class series: 15 to 150 HP (7.5 to 90 kW) in 10 types, 400 V class series: 15 to 450 HP (7.5 to 220 kW) in 14 types, Total 24 types...
  • Page 175 4.4 Selecting Options < Charging resistor > < Fuse > 4-41...
  • Page 176 Generated loss In CT mode PW M converter Boosting reactor Filtering reactor Filtering resistor Generated Generated Generated Generated Type Type Type Type Q'ty loss (W ) loss (W) loss (W) loss (W) RHC7.5-2C LR2-7.5C LFC2-7.5C GRZG80 0.42Ω RHC11-2C LR2-15C LFC2-15C GRZG150 0.2Ω...

  • Page 177: Dc Reactors (Dcrs)

    4.4 Selecting Options 4.4.1.3 DC reactors (DCRs) A DCR is mainly used for power supply matching and for input power factor correction (for reducing harmonic components). For power supply matching - Use a DCR when the capacity of a power supply transformer exceeds 500 kVA and is 10 times or more the rated inverter capacity.
  • Page 178 Table 4.11 DC Reactors (DCRs) The table below lists the combination of LD-mode inverters and DC reactors. Power Option/ Rated current Inductance Generated loss supply Inverter type DC reactor type Standard (mH) voltage FRN100G1S-2U DCR2-75C 0.05 230V FRN125G1S-2U Standard DCR2-90C 0.042 FRN150G1S-2U DCR2-110C...
  • Page 179 4.4 Selecting Options 4-45...

  • Page 180: Ac Reactors (Acrs)

    4.4.1.4 AC reactors (ACRs) Use an ACR when the converter part of the inverter should supply very stable DC power, for example, in DC link bus operation (shared PN operation). Generally, ACRs are used for correction of voltage waveform and power factor or for power supply matching, but not for suppressing harmonic components in the power lines.

  • Page 181: Zero-Phase Reactors For Reducing Radio Noise (Acls)

    4.4 Selecting Options 4.4.1.5 Zero-phase reactors for reducing radio noise (ACLs) An ACL is used to reduce radio frequency noise emitted by the inverter. An ACL suppresses the outflow of high frequency harmonics caused by switching operation for the power supply lines inside the inverter.

  • Page 182: Enclosed - Type 1 Kit

    4.4.1.6 Enclosed - Type 1 Kit [ 1 ] Overview Mounting the Enclosed - Type 1 Kit to a FRENIC-MEGA series general-purpose inverter provides inverter with a Type 1 Enclosure. [ 2 ] Configuration Note: To wire the control signal lines, remove the knockout plug. The mounting parts are slightly different for each model.

  • Page 183: 3 ] Specifications

    4.4 Selecting Options [ 3 ] Specifications This product can only be attached to FRENIC-MEGA (Standard inverter). The specifications to be changed are stated here. All the other specifications which are not mentioned are equivalent with FRENIC-MEGA (Standard inverter). Applicable inverters When an Enclosed - Type 1 Kit is installed to an inverter unit, the unit type changes to a type shown in a column "Inverter type after installation."...

  • Page 184: 4 ] Change Settings

    [ 4 ] Change settings Switch IP20/40 enclosure (Bit 7) For protection coordination, it is necessary to switch to the protection level suitable for the protection rating IP40 by setting Bit 7 (Switch IP20/IP40 enclosure) of function code H98. (Protection/Maintenance Function (Mode selection)) to "1"...

  • Page 185: Options For Operation And Communication

    Model: RJ-13 (BA-2 B-characteristics, 1 k ) Unit: inch (mm) Note: The dial plate and knob must be ordered as separated items. Available from Fuji Electric Technica Co., Ltd. Model: WAR3W (3W B-characteristics, 1 k ) Unit: inch (mm) Note: The dial plate and knob must be ordered as separated items.
  • Page 186 Figure 4.12 Dimensions of External Frequency Command Potentiometer and Connection Example 4-52...

  • Page 187: Extension Cable For Remote Operation

    4.4 Selecting Options 4.4.2.2 Extension cable for remote operation The extension cable connects the inverter with the keypad (standard or remote) or USB RS-485 converter to enable remote operation of the inverter. The cable is a straight type with RJ-45 jacks and its length is selectable from 16, 9.8, and 3.3 ft (5, 3, and 1 m).

  • Page 188: Inverter Support Loader Software

    4.4.2.3 Inverter support loader software FRENIC Loader is support software which enables the inverter to be operated via the RS-485 communications facility. The main functions include the following: - Easy editing of function code data - Monitoring the operation statuses of the inverter such as I/O monitor and multi-monitor - Operation of inverters on a PC screen (Windows-based only) Refer to Chapter 8 "RUNNING THROUGH RS-485 COMMUNICATION"...

  • Page 189: Pg Interface Card (Opc-G1-Pg)

    4.4 Selecting Options 4.4.2.4 PG interface card (OPC-G1-PG) The PG interface card has a two-shifted pulse train (ABZ phase) input circuit for speed feedback and a power output circuit for feeding power to the connected PG (pulse generator). Mounting this interface card on the FRENIC-MEGA enables the following: (1) Speed control (vector control with speed sensor, V/f control with speed sensor, dynamic torque vector control with speed sensor) using PG feedback signals, and servo-lock function...
  • Page 190 Terminal functions Terminal Name Specification Power input terminal from the external device for PG +12 VDC 10% or [P1] External power input * +15 VDC 10% (Use the power source 150 mA or above which is larger than the PG current consumption.) Power output terminal for PG [PO] Power output to PG *...
  • Page 191 4.4 Selecting Options Drive control Speed control (Vector control with speed sensor, V/f control with speed sensor, and Dynamic torque vector control with speed sensor) To control the motor speed, the inverter equipped with this interface card detects feedback signals sent from the PG (pulse generator) mounted on the motor output shaft, enabling high-response speed control.

  • Page 192: Pg Interface (5 V Line Driver) Card (Opc-G1

    4.4.2.5 PG interface (5 V line driver) card (OPC-G1-PG2) The PG interface (5 V line driver) card has the following circuits: - Shifted phase pulse train (A, B, and Z phases) input circuit for speed feedback (5 V line driver output type PG) - Wire break detection circuit (Detection of wire breaks on the Z phase can be cancelled.) - Power output circuit for feeding power to the connected PG (pulse generator)
  • Page 193 4.4 Selecting Options Terminal functions Terminal Name Specification Power input terminal from the external device for PG [P1] External power input * +5 VDC 10% input * (Use the power supply 200 mA or above which is larger than the PG current consumption.) Power output terminal for PG [PO] Power output to PG...
  • Page 194 Internal block diagram Shown below is the internal block diagram example where the internal power source (5 V) supplies power to the PG. (J1 is set to the INT position.) Each phase input circuit has a wire break detector. The A- and B-phase wire break detectors are always ON.
  • Page 195 4.4 Selecting Options Drive control Speed control (Vector control with speed sensor, V/f control with speed sensor, and Dynamic torque vector control with speed sensor) To control the motor speed, the inverter equipped with this interface card detects feedback signals sent from the PG (pulse generator) mounted on the motor output shaft, decomposes the motor drive current into the exciting and torque current components, and controls each of components in vector, enabling high-accuracy and high-response speed control.

  • Page 196: Pg Interface (5 V Line Driver X 2) Card (Opc-G1

    4.4.2.6 PG interface (5 V line driver x 2) card (OPC-G1-PG22) The PG interface (5 V line driver x 2) card has the following circuits: - Shifted phase pulse train (YA, YB, YZ, and XA, XB, XZ) input circuit for speed feedback (5 V line driver output type PG) - Wire break detection circuit (Detection of wire breaks on the YZ, XA, XB, and XZ phases can be cancelled.)
  • Page 197 4.4 Selecting Options Pulse train input interface specifications Item Specifications Maximum response frequency 100 kHz Pulse output system Line driver (Equivalent to 26C31 or 26LS31) Pulse train Source current: +20 mA (max.) generator Sink current: -20 mA (max.) Maximum wiring length 328 ft (100 m) Terminal functions Terminal...
  • Page 198 Internal block diagram Shown below is the internal block diagram example where the internal power source (5 V) supplies power to the PG. (J1 is set to the INT position.) Each phase input circuit has a wire break detector. The YA- and YB-phase wire break detectors are always ON.

  • Page 199: Relay Output Interface Card (Opc-G1-Ry)

    4.4 Selecting Options 4.4.2.7 Relay output interface card (OPC-G1-RY) The relay output interface card converts an inverter’s digital output to a mechanical contact (one transfer contact) output. It has two independent transfer contacts so that using two cards allows the user to activate up to four contact outputs.
  • Page 200 Internal circuits [1A] [Y1]/[Y3] signal [1B] Actuator [1C] [2A] [Y2]/[Y4] signal [2B] Actuator [2C] Figure 4.16 Internal Circuits The relationship between function codes and relay output functions is as follows. Function code Functions Setting range Terminal [Y1] (Function selection) Terminal [Y2] (Function selection) 0 to 105 (For normal logic), or 1000 to 1105 (For negative logic) Terminal [Y3] (Function selection)

  • Page 201: Digital Input Interface Card (Opc-G1-Di)

    4.4 Selecting Options 4.4.2.8 Digital input interface card (OPC-G1-DI) The digital input interface card has 16 digital input terminals (switchable between SINK and SOURCE). Mounting this interface card on the FRENIC-MEGA enables the user to specify frequency commands with binary code (8, 12, 15, or 16 bits) or BCD (4-bit Binary Coded Decimal) code. Ports available for the interface card This interface card can be connected to any one of the three option connection ports (A-, B-, and C-ports) on the FRENIC-MEGA.
  • Page 202 Connection example Connection example Power supply SINK mode SOURCE mode [P L C ] M E G A Inte rfa ce ca rd [M 1] In te rfa c e c ard [M 1 ] + 2 4 V + 24 V S IN K S IN K S O U R C E...
  • Page 203 4.4 Selecting Options Input signal name Terminal function and configuration details Frequency can be specified within the range of 0 to 500.0 4-digit BCD Hz (Setting resolution = 0.1 Hz). 0, 1 frequency command If a frequency command exceeding the maximum (0 to 500.0 Hz) frequency is input, the maximum frequency applies.

  • Page 204: Digital Output Interface Card (Opc-G1-Do)

    4.4.2.9 Digital output interface card (OPC-G1-DO) The digital output interface card has eight transistor output terminals (switchable between SINK and SOURCE). Mounting this interface card on the FRENIC-MEGA enables the user to monitor the output frequency and other items with binary code (8 bits). Ports available for the interface card This interface card can be connected to any of the three option connection ports (A-, B-, and C-ports) on the FRENIC-MEGA.
  • Page 205 4.4 Selecting Options Connection example Interface card [M2] SINK mode [O1] to [O8] 24 V Interface card [M2] 24 V SOURCE mode [O1] to [O8] Configuring inverter's function code Function code o21 (DO mode selection) provided for options specifies the item to be monitored by digital signals of this interface card.

  • Page 206: Analog Interface Card (Opc-G1-Aio)

    4.4.2.10 Analog interface card (OPC-G1-AIO) The analog interface card has the terminals listed below. Mounting this interface card on the FRENIC-MEGA enables analog input and analog output to/from the inverter. - One analog voltage input point (0 to 10 V) - One analog current input point (4 to 20 mA) - One analog voltage output point (0 to 10 V) - One analog current output point (4 to 20 mA)
  • Page 207 4.4 Selecting Options Symbol Name Functions Remarks - Outputs the monitor signal of analog DC voltage (0 to 10 VDC). - One of the following signals can be issued from this terminal. - Output frequency (before or after slip compensation) - Output current - Output voltage - Output torque...
  • Page 208 Connection example Symbol Connection of shielded wire Shielded wire [P10] Potentiom eter [32] [32] 1k to 5k [31] Shielded wire [C2] Constant current source [C2] 4 to 20 m A [31] Shielded wire [Ao+] [Ao] [Ao-] Shielded wire [CS+] [CS] [CS-] Function code settings Function Codes and Their Parameters for Terminal [32]...
  • Page 209 4.4 Selecting Options Function Codes and Their Parameters for Terminal [32] (Continued) Function Name Data Description Remarks code (Offset adjustment) -5.0 to +5.0% Offset adjustment amount (Gain adjustment) 0.00 to 200.00% Gain adjustment amount (Filter setting) 0.00 to 5.00 s Filter constant (Gain base point) 0.00 to 100.00%...
  • Page 210 Function Codes and Their Parameters for Terminal [Ao] (Continued) Function Name Data Description Remarks code (Gain to output voltage) 0 to 300% (Polarity) 0 Bipolar Unipolar Function Codes and Their Parameters for Terminal [CS] Function Name Data Description Remarks code Terminal [CS] function Output frequency 1 (before slip compensation)

  • Page 211: T-Link Communications Card (Opc-G1-Tl)

    4.4 Selecting Options 4.4.2.11 T-Link communications card (OPC-G1-TL) The T-Link communications card is used to connect the FRENIC-MEGA series to a Fuji MICREX series of programmable logic controllers via a T-Link network. Mounting the communications card on the FRENIC-MEGA enables the user to specify and monitor run and frequency commands and configure and check inverter's function codes required for inverter running from the MICREX.
  • Page 212 Inverter's function codes dedicated to T-Link communication Function Data setting Function Description range * code Select run/frequency 0 to 3 Select from the following choices: command sources Frequency command Run command source source Inverter Inverter T-Link Inverter Inverter T-Link T-Link T-Link Immediately coast to a stop and trip with er5 .
  • Page 213 4.4 Selecting Options G9 compatible format When the G9 (FRENIC5000 G9) compatible format is selected (o30 = 2), an eight-word area per inverter is used in the I/O relay area as shown below. The lower four words are status area for reading out data from the inverter to the MICREX;...

  • Page 214: Sx-Bus Communications Card (Opc-G1-Sx)

    4.4.2.12 SX-bus communications card (OPC-G1-SX) The SX-bus communications card is used to connect the FRENIC-MEGA series to a Fuji MICREX-SX series of programmable logic controllers via an SX bus. Mounting the communications card on the FRENIC-MEGA enables programmed control and monitoring of the inverter and configuring and checking of function codes required for inverter running, from the MICREX-SX.
  • Page 215 4.4 Selecting Options Inverter's function codes dedicated to SX-bus communication Function Data setting Function Description code range * Select run/frequency 0 to 3 Select from the following choices: command sources Frequency Run command command source source Inverter Inverter SX bus Inverter Inverter SX bus...
  • Page 216 Area occupied in MICREX-SX and data allocation address Standard Format When the standard format is selected (o30 = 0), SX-bus communication uses a 16-word area per inverter in the MICREX-SX I/O area as shown below. (A maximum of 10 inverters can be connected.) The lower 8-word area is used as a status area for reading out data from the inverter to the MICREX-SX, the upper 8-word one, as a control area for writing data from the MICREX-SX to the inverter.

  • Page 217: Cc-Link Communications Card (Opc-G1-Ccl)

    4.4 Selecting Options 4.4.2.13 CC-Link communications card (OPC-G1-CCL) CC-Link (Control & Communication Link) is an FA open field network system. The CC-Link communications card connects the inverter to a CC-Link master via CC-Link using a dedicated cable. It supports the transmission speed of 156 kbps to 10 Mbps and the total length of 328 to 3,900 ft (100 to 1,200 m) so that it can be used in wide range of systems requiring a high-speed or long-distance transmission, enabling a flexible system configuration.
  • Page 218 Inverter's function codes dedicated to CC-Link communication Function Data setting Function Description range * code Select run/frequency 0 to 3 Select from the following choices: command sources Frequency Run command command source source Inverter Inverter CC-Link Inverter Inverter CC-Link CC-Link CC-Link Immediately coast to a stop and trip with er5 .

  • Page 219: Profibus-Dp Communications Card (Opc-G1-Pdp)

    4.4 Selecting Options 4.4.2.14 PROFIBUS-DP communications card (OPC-G1-PDP) The PROFIBUS-DP communications card is used to connect the FRENIC-MEGA series to a PROFIBUS-DP master via PROFIBUS. Mounting the communications card on the FRENIC-MEGA enables the user to control the FRENIC-MEGA as a slave unit by configuring and monitoring run and frequency commands and accessing inverter's function codes from the PROFIBUS master.
  • Page 220 Inverter's function codes dedicated to PROFIBUS-DP communication The inverter's function codes listed in Table 4.19 should be configured for specifying run and frequency commands via PROFIBUS. Table 4.19 Inverter's Function Codes Required for Enabling Run and Frequency Commands via PROFIBUS Function Factory Function code...
  • Page 221 4.4 Selecting Options Node address (1) Configuring node address switches (SW1 and SW2) Before the inverter power is turned ON, the node address of the communications card should be specified with SW1 and SW2 (rotary switches) on the card. The setting range is from 00 to 99 in decimal. SW1 specifies a 10s digit of the node address and the SW2, a 1s digit.

  • Page 222: Devicenet Communications Card (Opc-G1-Dev)

    256 ft (78 m) 512 ft (156 m) 1. I/O Message (Poll, Change of State) Messages supported 2. Explicit Message Vendor ID 319 (Registered name: Fuji Electric Group) Device type AC drive (code: 2) Product code 9219 Applicable device profile AC Drive Max.
  • Page 223 4.4 Selecting Options DIP switch configuration The DIP switch specifies the communication data rate (baud rate) and the node address (MAC ID) on DeviceNet as shown below. It offers a choice of baud rates (125, 250, and 500 kbps) and a choice of node address (MAC ID) ranging from 0 to 63.
  • Page 224 Table 4.21 Function Code Group Group Group Group Group Group name Group Group name Group Group name code code code 2 02h Command/function data 9 09h Motor 2 parameters 19 13h Motor 3 parameters 3 03h Monitored data 10 0Ah Option functions 12 0Ch Motor 4 parameters 4 04h Fundamental functions 14 0Eh Application functions 1...

  • Page 225: Canopen Communications Card (Opc-G1-Cop)

    4.4 Selecting Options 4.4.2.16 CANopen communications card (OPC-G1-COP) The CANopen communications card is used to connect the FRENIC-MEGA series to a CANopen master unit (e.g., PC and PLC) via a CANopen network. Mounting the communications card on the FRENIC-MEGA allows the user to control the FRENIC-MEGA as a slave unit by configuring run and frequency commands and accessing inverter's function codes from the CANopen master unit.
  • Page 226 The table below lists the other related inverter's function codes. Configure those function codes if necessary. Related Inverter's Function Codes Function Factory Function code name default Data setting range Description code Select error processing 0 to 15 for CANopen network breaks Set the operation timer 0 to 60.0 s...
  • Page 227 4.4 Selecting Options Communication The communications card is a slave of CANopen and supports the following services. Item Services Remarks - 3 RPDOs / 3 TPDOs All PDO cannot be remapped by PDO Mapping parameters. - Sync, Cyclic and Async (Change of state event) supported for 3 TPDOs - Expedited and Segmented protocol Block protocol not supported...

  • Page 228: List Of Option Cards And Connection Ports

    List of Option Cards and Connection Ports The table below lists the option cards and option connection ports. (Function enhancement or version update in the future may provide new options. For options not listed below, contact Fuji Electric.) Option connection ports Option type...

  • Page 229: Meter Options

    Model: TRM-45 (10 VDC, 1 mA) This model has two types of calibration: "0 to 60/120 Hz" and "60/120/240 Hz." Unit: inch (mm) Available from Fuji Electric Technica Co., Ltd. Model: FMN-60 (10 VDC, 1 mA) Model: FMN-80 (10 VDC, 1 mA)
  • Page 230 Figure 4.17 Frequency Meter Dimensions and Connection Example 4-96...

  • Page 231: Function Codes

    Chapter 5 FUNCTION CODES This chapter contains overview tables of function codes available for the FRENIC-MEGA series of inverters, function code index by purpose, and details of function codes. Contents 5.1 Overview of Function Codes ......................... 5-1 5.2 Function Code Tables ..........................5-2 5.3 Function Code Index by Purpose ......................
  • Page 232 5.3.18 Maintenance ..........................5-58 5.3.18.1 Maintenance of inverters ...................... 5-58 5.3.18.2 Maintenance of machinery ....................5-58 5.4 Details of Function Codes ........................5-59 5.4.1 F codes (Fundamental functions) ....................5-59 5.4.2 E codes (Extension terminal functions)..................5-116 5.4.3 C codes (Control functions) ....................... 5-158 5.4.4 P codes (Motor 1 parameters) .....................

  • Page 233: Overview Of Function Codes

    5.1 Overview of Function Codes 5.1 Overview of Function Codes Function codes enable the FRENIC-MEGA series of inverters to be set up to match your system requirements. Each function code consists of a 3-letter alphanumeric string. The first letter is an alphabet that identifies its group and the following two letters are numerals that identify each individual code in the group.

  • Page 234: Function Code Tables

    5.2 Function Code Tables The following descriptions supplement those given in the function code tables on page 5-4 and subsequent pages. Changing, validating, and saving function code data when the inverter is running Function codes are indicated by the following based on whether they can be changed or not when the inverter is running: Notation Change when running...
  • Page 235 5.2 Function Code Tables Using negative logic for programmable I/O terminals The negative logic signaling system can be used for the programmable, digital input and output terminals by setting the function code data specifying the properties for those terminals. Negative logic refers to the inverted ON/OFF (logical value 1 (true)/0 (false)) state of input or output signal.
  • Page 236 Note: Difference of notation between standard keypad and remote keypad Descriptions in this manual are based on the standard keypad having an LCD monitor and a five-digit, 7-segment LED monitor (as shown in Chapter 3). The FRENIC-MEGA also provides a remote keypad as an option, which has no LCD monitor and has a four-digit, 7-segment LED and a USB port.
  • Page 237 5.2 Function Code Tables The following tables list the function codes available for the FRENIC-MEGA series of inverters. F codes: Fundamental Functions Drive control Refer Default Code Name Data setting range setting Torque page: control F00 Data Protection 0: Disable both data protection and digital reference 5-34 protection 1: Enable data protection and disable digital reference...
  • Page 238 Drive control Refer Default Code Name Data setting range setting Torque page: control F23 Starting Frequency 1 0.0 to 60.0 Hz 5-59 (Holding time) 0.00 to 10.00 s 0.00 F25 Stop Frequency 0.0 to 60.0 Hz F26 Motor Sound (Carrier frequency) 0.75 to 16 kHz (LD-mode inverters of 0.5 to 30 HP and 5-62 HD-mode ones of 0.5 to 100 HP) 0.75 to 10 kHz (LD-mode inverters of 40 to 100 HP and...
  • Page 239 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control F43 Current Limiter (Mode selection) 0: Disable (No current limiter works.) 5-75 1: Enable at constant speed (Disable during ACC/DEC) 2: Enable during ACC/constant speed operation (Level) 20% to 200% (The data is interpreted as the rated output current of the inverter for 100%.) F50 Electronic...
  • Page 240 E codes: Extension Terminal Functions Drive control Refer Default Code Name Data setting range setting Torque page: control Selecting function code data assigns the corresponding 5-79 function to terminals [X1] to [X7] as listed below. E01 Terminal [X1] Function 0 (1000): Select multi-frequency (0 to 1 steps) (SS1) E02 Terminal [X2] Function 1 (1001): Select multi-frequency (0 to 3 steps)
  • Page 241 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control E10 Acceleration Time 2 0.00 to 6000 s 5-45 Note: Entering 0.00 cancels the acceleration time, requiring E11 Deceleration Time 2 5-90 external soft-start and -stop. E12 Acceleration Time 3 E13 Deceleration Time 3 E14 Acceleration Time 4...
  • Page 242 Drive control Refer Default Code Name Data setting range setting Torque page: control 70 (1070): Speed valid (DNZS) 5-91 71 (1071): Speed agreement (DSAG) 72 (1072): Frequency (speed) arrival signal 3 (FAR3) 76 (1076): PG error detected (PG-ERR) 82 (1082): Positioning completion signal (PSET) 84 (1084): Maintenance timer (MNT)
  • Page 243 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control E50 Coefficient for Speed Indication 0.01 to 200.00 30.00 5-102 E51 Display Coefficient Input 0.000 (Cancel/reset), 0.001 to 9999 0.010 Watt-hour Data E52 Keypad (Menu display mode) 0: Function code data editing mode (Menus #0, #1, and #7) 1: Function code data check mode (Menus #2 and #7) 2: Full-menu mode...
  • Page 244 Drive control Refer to Default Code Name Data setting range page: setting Torque control 30 (1030): Force to stop (STOP) 5-79 ((30 = Active OFF, 1030 = Active ON) 5-106 32 (1032): Pre-excitation (EXITE) 33 (1033): Reset PID integral and differential components (PID-RST) 34 (1034): Hold PID integral component...
  • Page 245 5.2 Function Code Tables C codes: Control Functions of Frequency Drive control Refer Default Code Name Data setting range setting Torque page: control C01 Jump Frequency 1 0.0 to 500.0 Hz 5-107 (Hysteresis width) 0.0 to 30.0 Hz C05 Multi-frequency 1 0.00 to 500.00 Hz 0.00 0.00...
  • Page 246 P codes: Motor 1 Parameters Drive control Refer Default Code Name Data setting range setting Torque page: control P01 Motor 1 (No. of poles) 2 to 22 poles Y1 Y2 5-111 (Rated capacity) 0.01 to 1000 kW (when P99 = 0, 2, 3 or 4) Y1 Y2 0.01 to 1000 HP (when P99 = 1) (Rated current) 0.00 to 2000 A...
  • Page 247 5.2 Function Code Tables H codes: High Performance Functions Drive control Refer Default Code Name Data setting range setting Torque page: control H03 Data Initialization 0: Disable initialization 5-116 1: Initialize all function code data to the factory defaults 2: Initialize motor 1 parameters 3: Initialize motor 2 parameters 4: Initialize motor 3 parameters 5: Initialize motor 4 parameters...
  • Page 248 Drive control Refer Default Code Name Data setting range setting Torque page: control H49 Starting Mode 0.0 to 10.0 s 5-119 (Auto search delay time 1) 5-127 H50 Non-linear V/f Pattern 1 (Frequency) 0.0: Cancel, 0.1 to 500.0 Hz 5-43 (Voltage) 0 to 240: Output an AVR-controlled voltage 5-127 (for 230 V series)
  • Page 249 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control H73 Torque Limiter 0: Enable during ACC/DEC and running at constant speed 5-66 (Operating conditions) 5-129 1: Disable during ACC/DEC and enable during running at constant speed 2: Enable during ACC/DEC and disable during running at constant speed...
  • Page 250 A codes: Motor 2 Parameters Drive control Refer Default Code Name Data setting range setting Torque page: control A01 Maximum Frequency 2 25.0 to 500.0 Hz 60.0 ― A02 Base Frequency 2 25.0 to 500.0 Hz 60.0 A03 Rated Voltage at Base Frequency 2 0: Output a voltage in proportion to input voltage 80 to 240: Output an AVR-controlled voltage (for 230 V series)
  • Page 251 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control A18 Motor 2 (Auto-tuning) 0: Disable ― 1: Tune while the motor stops. (%R1, %X and rated slip frequency) 2: Tune while the motor is rotating under V/f control (%R1, %X, rated slip frequency, no-load current, magnetic saturation factors 1 to 5, and magnetic saturation extension factors "a"...
  • Page 252 b codes: Motor 3 Parameters Drive control Refer Default Code Name Data setting range setting Torque page: control b01 Maximum Frequency 3 25.0 to 500.0 Hz 60.0 ― b02 Base Frequency 3 25.0 to 500.0 Hz 60.0 b03 Rated Voltage at Base Frequency 3 0: Output a voltage in proportion to input voltage 80 to 240: Output an AVR-controlled voltage (for 230 V series)
  • Page 253 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control (Iron loss factor 2) 0.00% to 20.00% Y1 Y2 0.00 ― (Iron loss factor 3) 0.00% to 20.00% Y1 Y2 0.00 (Magnetic saturation factor 1) 0.0% to 300.0% Y1 Y2 (Magnetic saturation factor 2) 0.0% to 300.0% Y1 Y2...
  • Page 254 r codes: Motor 4 Parameters Drive control Refer Default Code Name Data setting range setting Torque page: control r01 Maximum Frequency 4 25.0 to 500.0 Hz 60.0 ― r02 Base Frequency 4 25.0 to 500.0 Hz 60.0 r03 Rated Voltage at Base Frequency 4 0: Output a voltage in proportion to input voltage 80 to 240: Output an AVR-controlled voltage (for 230 V series)
  • Page 255 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control (Iron loss factor 2) 0.00% to 20.00% Y1 Y2 0.00 ― (Iron loss factor 3) 0.00% to 20.00% Y1 Y2 0.00 (Magnetic saturation factor 1) 0.0% to 300.0% Y1 Y2 (Magnetic saturation factor 2) 0.0% to 300.0% Y1 Y2...
  • Page 256 J codes: Application Functions 1 Drive control Refer Default Code Name Data setting range setting Torque page: control J01 PID Control (Mode selection) 0: Disable 5-140 1: Enable (Process control, normal operation) 2: Enable (Process control, inverse operation) 3: Enable (Dancer control) (Remote command SV) 0: keys on keypad 5-141...
  • Page 257 5.2 Function Code Tables d codes: Application Functions 2 Drive control Refer Default Code Name Data setting range setting Torque page: control d01 Speed Control 0.000 to 5.000 s 0.020 5-159 (Speed command filter) (Speed detection filter) 0.000 to 0.100 s 0.005 P (Gain) 0.1 to 200.0 times 10.0...
  • Page 258 Drive control Refer Default Code Name Data setting range setting Torque page: control d71 Synchronous Operation 0.00 to 1.50 times 1.00 5-166 (Main speed regulator gain) (APR P gain) 0.00 to 200.00 times 1500 (APR positive output limiter) 20 to 200%, 999: No limiter (APR negative output limiter) 20 to 200%, 999: No limiter (Z phase alignment gain) 0.00 to 10.00 times 1.00...
  • Page 259 5.2 Function Code Tables U codes: Application Functions 3 Drive control Refer Default Code Name Data setting range setting Torque page: control U00 Customizable Logic (Mode selection) 0: Disable 5-167 1: Enable (Customizable logic operation) U01 Customizable Logic: (Input 1) 0 (1000): Inverter running (RUN) U02 Step 1 (Input 2) 1 (1001): Frequency (speed) arrival signal...
  • Page 260 Drive control Refer Default Code Name Data setting range setting Torque page: control 84 (1084): Maintenance timer (MNT) 5-167 98 (1098): Light alarm (L-ALM) 99 (1099): Alarm output (for any alarm) (ALM) 101 (1101): Enable circuit failure detected (DECF) 102 (1102): Enable input OFF (EN OFF) 105 (1105): Braking transistor broken (DBAL)
  • Page 261 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting Torque page: control U11 Customizable Logic: (Input 1) See U01. See U01. 5-167 U12 Step 3 (Input 2) See U02. See U02. (Logic circuit) See U03. (Type of timer) See U04.
  • Page 262 Drive control Refer Default Code Name Data setting range setting Torque page: control U81 Customizable Logic Output Signal 1 0 (1000): Select multi-frequency (0 to 1 step) (SS1) 5-167 (Function selection) 1 (1001): Select multi-frequency (0 to 3 steps) (SS2) U82 Customizable Logic Output Signal 2 2 (1002): Select multi-frequency (0 to 7 steps) (SS4) U83 Customizable Logic Output Signal 3 3 (1003): Select multi-frequency (0 to 15 steps)
  • Page 263 5.2 Function Code Tables Drive control Refer Default Code Name Data setting range setting page: Torque U91 Customizable Logic Timer Monitor 1: Step 1 5-167 (Step selection) 2: Step 2 3: Step 3 4: Step 4 5: Step 5 6: Step 6 7: Step 7 8: Step 8 9: Step 9...
  • Page 264 y codes: LINK Functions Drive control Refer Default Code Name Data setting range setting Torque page: control y01 RS-485 Communication 1 to 255 5-176 (Station address) (Communications error processing) 0: Immediately trip with alarm er8 1: Trip with alarm er8 after running for the period specified by timer y03 2: Retry during the period specified by timer y03.
  • Page 265 5.2 Function Code Tables Table A Factory Defaults Depending upon Inverter Capacity Auto-restart after Auto-restart after Inverter Inverter momentary power momentary power capacity capacity failure failure 1000 Function Code Tables F codes E codes C codes P codes H codes A codes b codes r codes...
  • Page 266 Table B Motor Parameters When the "HP rating motors" is selected with P99/A39/b39/r39 (data = 1) Three-phase 230 V series (FRN_ _ _G1 -2U) Note: A box ( ) replaces S or H depending on the enclosure. 5-34...
  • Page 267 5.2 Function Code Tables Table B Motor Parameters (Continued) Three-phase 460 V series (FRN_ _ _G1 -4U) Note: A box ( ) replaces S or H depending on the enclosure. 5-35...

  • Page 268: Function Code Index By Purpose

    5.3 Function Code Index by Purpose 5.3.1 Configuring the minimal requirements for the inverter to just run the motor To run the motor simply with constant torque load under V/f control, the following function codes should be configured as minimal requirements. These function codes are displayed in the quick setup (Menu #0). Function Refer to Name...

  • Page 269: Frequency Setting By Analog Input

    5.3 Function Code Index by Purpose 5.3.2.2 Frequency setting by analog input Function Refer to Name code page: Set up the reference frequency using analog input (voltage or Frequency Command 1 5-57 current) applied to terminal [12], [C1], or [V2] from external equipment (analog frequency command source).

  • Page 270: Entering A Run Command

    Function Refer to Name code page: Set up the reference frequency with pulse train Frequency Command 1 5-57 input. Command (Pulse Rate Input) 5-221 (Pulse input format) (Filter time constant) (Pulse count factor 1) Pulse train input (Pulse count factor 2) Receive pulses from other motor's PG to perform ratio operation.

  • Page 271: Starting/Stopping The Motor

    5.3 Function Code Index by Purpose 5.3.4 Starting/stopping the motor Function Refer to Name code page: Starting Starting Frequency 1 Start the motor smoothly. 5-87 frequency Starting Frequency 1 (Holding time) Starting Mode 5-163 (Auto search) (Auto search delay time 1) Search for the idling motor speed to restart the Auto search (Auto search delay time 2)

  • Page 272: Adjusting The Running Performance

    Function Refer to Name code page: Allow the motor to coast to a stop when the Deceleration Mode 5-165 run command is turned OFF in order to minimize the variation of deceleration torque. Coast-to-stop Allow the motor to coast to a stop in order to prevent conflict with the mechanical brake.

  • Page 273: Controlling The Motor

    5.3 Function Code Index by Purpose Function Refer to Name code page: Suppression of Output Current Fluctuation Damping 5-181 Suppress the fluctuation of the inverter output output current Gain for Motor 1 current. fluctuation Motor Sound Reduce an audible noise generated by the Motor sound (Carrier frequency) 5-90...

  • Page 274: Motor Parameters To Be Set Up

    Function Refer to Name code page: Motor/Parameter Switching 2 5-190 ASR Switching Time E01-E07 Terminals [X1] to [X7] Functions 5-111 (M2) Speed Control 1 (Speed command filter) (Speed detection filter) 5-212 Switch the gain and other speed control P (Gain) I (Integral time) parameters between two control modes.

  • Page 275: Setting Up I/O Terminals

    5.3 Function Code Index by Purpose Function Refer to Name code page: Motor 1 5-157 (No-load current) (%R1) (%X) 5-159 P53, P54 (%X correction factor 1, 2) 5-158 (Slip compensation gain for driving) (Slip compensation response time) (Slip compensation gain for Set up motor parameters according to tuning or the motor braking) manufacturer's data sheet.

  • Page 276: Keeping On Running The Motor

    5.3.10 Keeping on running the motor Function Refer to Name code page: Auto-reset 5-161 Enable the auto-reset function that makes the (Times) inverter automatically attempt to reset the (Reset interval) Reset tripped state and restart even if an alarm E20-E24 Terminal [Y1] to [Y5A/C] Functions 5-128 occurs.

  • Page 277: Outputting Status Signals

    5.3 Function Code Index by Purpose 5.3.11 Outputting status signals Function Refer to Name code page: Frequency Detection 1 5-139 (Level) (Hysteresis width) Detection of Frequency Detection 2 (Level) Detect the motor running speed level. frequency Frequency Detection 3 (Level) E20-E24 Terminal [Y1] to [Y5A/C] Functions 5-128...

  • Page 278: Running In Various Operation Modes

    5.3.12 Running in various operation modes Function Refer to Name code page: Jog (inch) the motor with the keys on the Jogging Frequency 5-152 keypad. Acceleration Time (Jogging) 5-69 Jogging Deceleration Time (Jogging) Jog (inch) the motor with input signals to Terminal [X1] to [X7] Functions E01-E07 5-111...
  • Page 279 5.3 Function Code Index by Purpose Function Refer to Name code page: E01-E07 Terminal [X1] to [X7] Functions 5-111 (Hz2/Hz1) E20-E24 Terminal [Y1] to [Y5A/C] Functions 5-128 (SY) Feedback Input (Pulse input format) (Encoder pulse resolution) 5-215 (Pulse count factor 1) (Pulse count factor 2) Application-defined Control 5-???

  • Page 280: Setting Up Controls Suited For Individual Applications

    5.3.13 Setting up controls suited for individual applications 5.3.13.1 Droop control Function Refer to Name code page: Droop Control 5-169 Terminals [X1] to [X7] Functions Eliminate load unbalance using droop control. E01-E07 5-111 (DROOP) 5.3.13.2 PID process control Refer to Code Name page:...
  • Page 281 5.3 Function Code Index by Purpose Refer to Code Name page: PID Control (Remote command SV) 5-194 E01-E07 Terminal [X1] to [X7] Functions 5-111 Define two or more PID commands (SS4, SS8) PID command beforehand and switch between them with Multi-frequency 4 5-150 "Select multi-frequency"...

  • Page 282: Pid Dancer Control

    Refer to Code Name page: Hold/reset the PID processor or cancel PID E01-E07 Terminal [X1] to [X7] Functions 5-111 PID control control from external equipment. (PID-HLD, Hz/PID, PID-RST) "Under PID E20-E24 Terminal [Y1] to [Y5A/C] Functions 5-128 Output the "Under PID control" signal from control"...
  • Page 283 5.3 Function Code Index by Purpose Function Refer to Name code page: PID Control (Remote command SV) 5-194 E01-E07 Terminal [X1] to [X7] Functions 5-111 Define two or more PID commands (SS4, SS8) PID command beforehand and switch between them with Multi-frequency 4 5-150 "Select multi-frequency"...

  • Page 284: Customizing The Keypad

    Function Refer to Name code page: "Under PID E20-E24 Terminal [Y1] to [Y5A/C] Functions 5-128 Output the "Under PID control" signal from control" signal (PID-CTL) the specified output terminal. output Convert a control amount into a physical PID Display Coefficient A Display of quantity of the process and display it on the PID Display Coefficient B...

  • Page 285: Controlling The Inverter Via Communications Line

    5.3 Function Code Index by Purpose 5.3.15 Controlling the inverter via communications line Function Refer to Name code page: RS-485 Communication 1 5-244 (Station address) (Communications error processing) (Timer) (Baud rate) (Data length) (Parity check) (Stop bits) (No-response error detection time) (Response interval) (Protocol selection) <...

  • Page 286: Using The Customizable Logic

    5.3.16 Using the customizable logic Function Refer to Name code page: Enable the sequence configured by the customizable logic Customizable Logic (Mode 5-222 function. * 2 selection) U01-U50 Customizable Logic: Steps 1 to 10 5-222 (Mode selection) U71-U75 Customizable Logic Output Signals 1 to 5 (Output selection) U81-U85 Customizable Logic Output Signals...

  • Page 287: Protection Of Motors

    5.3 Function Code Index by Purpose Function Refer to Name code page: Torque Limiter 1-1 5-96 Torque Limiter 1-2 Torque Limiter 2-1 Torque Limiter 2-1 Terminal [12] Extended Function 5-146 Terminal [C1] Extended Function Terminal [V2] Extended Function Torque Limiter Limit the motor output torque with the torque limiter to protect 5-96 (Operating conditions)

  • Page 288: Using Other Protective And Safety Functions

    Function Refer to Name code page: Dew Condensation Prevention 5-206 (Duty) Prevent the motor being stopped from dew DC Braking 1 5-85 condensation condensation by feeding DC power when the (Braking level) prevention motor is used in cold climates. (Braking time) 5-111 E01-E07 Terminal [X1] to [X7] Functions...
  • Page 289 5.3 Function Code Index by Purpose Function Refer to Name code page: Speed Agreement/PG Error 5-217 (Hysteresis width) Speed deviation Detect that a deviation between the reference (Detection timer) out of the speed and detected one is out of the specified PG Error Processing specified range range.

  • Page 290: Maintenance

    5.3.18 Maintenance 5.3.18.1 Maintenance of inverters Function Refer to Name code page: Set up the load conditions that match the Capacitance of DC Link Bus Service life of actual operating conditions at the user site for Capacitor DC link bus 5-172 measuring the service life of the DC link bus Initial Capacitance of DC Link Bus...

  • Page 291: Details Of Function Codes

    5.3 Function Code Index by Purpose 5.4 Details of Function Codes This section provides the details of the function codes. The descriptions are, in principle, arranged in the order of function code groups and in numerical order. However, highly relevant function codes are collectively described where one of them first appears.
  • Page 292 Frequency Command 1 F18 (Bias, Frequency command 1) C30 (Frequency Command 2) C31 to C35 (Analog Input Adjustment for [12]) C36 to C39 (Analog Input Adjustment for [C1]) C41 to C45 (Analog Input Adjustment for [V2]) C50 (Bias (Frequency command 1), Bias base point) H61 (UP/DOWN Control, Initial frequency setting) d59, d61 to d63 (Command (Pulse Rate Input)) F01 or C30 sets the command source that specifies reference frequency 1 or reference frequency...
  • Page 293 5.3 Function Code Index by Purpose The lowest digit blinks. Means the keypad takes precedence. Allowable entry range Operation guide Example of Reference Frequency Configuration Screen (3) To change the reference frequency, press the key again. To save the new setting into the inverter's memory, press the key (when E64 = 1 (factory default)).
  • Page 294 The table below lists the available command sources and their symbols. Available Command Sources Symbol Command source Symbol Command source Symbol Command source HAND Keypad MULTI Multi-frequency PID-HAND PID keypad command PID command 1 Terminal [12] PID-P1 (Analog command) PID command 2 RS485-1 RS-485 (Port 1) * 1 Terminal [C1] PID-P2...
  • Page 295 5.3 Function Code Index by Purpose Gain and bias If F01 = 3 (the sum of [12] + [C1] is enabled), the bias and gain are independently applied to each of the voltage and current inputs given to terminals [12] and [C1], and the sum of the two values is applied as the reference frequency.
  • Page 296 Example: Setting the bias, gain, and their base points when the reference frequency 0 to 60 Hz follows the analog input of 1 to 5 VDC applied on terminal [12] with the maximum frequency 60 Hz (F03) (Point A) To set the reference frequency to 0 Hz for an analog input being at 1 V, set the bias to 0% (F18 = 0).
  • Page 297 5.3 Function Code Index by Purpose In the case of bipolar input (terminal [12] with C35 = 0, terminal [V2] with C45 = 0) Setting C35 and C45 data to "0" enables terminals [12] and [V2] to be used for bipolar input (-10 V to +10 V), respectively.
  • Page 298 [ 3 ] Using digital input signals UP/DOWN (F01 = 7) When UP/DOWN control is selected for frequency setting with a run command ON, turning the terminal command UP or DOWN ON causes the output frequency to increase or decrease, respectively, within the range from 0 Hz to the maximum frequency as listed below.
  • Page 299 5.3 Function Code Index by Purpose <Initial frequency for UP/DOWN control when the frequency command source is switched> When the frequency command source is switched to UP/DOWN control from other sources, the initial frequency for UP/DOWN control is as listed below: Initial frequency for UP/DOWN control Frequency command Switching command...
  • Page 300 Pulse train sign/Pulse train input Forward rotation pulse/Reverse rotation pulse A and B phases with 90 degree phase difference Pulse count factor 1 (d62), Pulse count factor 2 (d63) For the pulse train input, function codes d62 (Command (Pulse rate input), (Pulse count factor 1)) and d63 (Command (Pulse rate input), (Pulse count factor 2)) define the relationship between the input pulse rate and the frequency command (reference).
  • Page 301 5.3 Function Code Index by Purpose As shown in the figure above, enter the pulse train input rate into function code d62 (Command (Pulse rate input), (Pulse count factor 1)), and enter the frequency reference defined by d62 into d63 (Command (Pulse rate input), (Pulse count factor 2)). The relationship between the pulse train input rate (kp/s) inputted to the PIN terminal and the frequency reference f* (Hz) (or speed command) is given by the expression below.
  • Page 302 Operation Method F02 selects the source that specifies a run command. The table below lists the run command sources and the rotational directions of the motor. Data for F02 Description Keypad Enables the , and keys to run the motor in the forward and reverse directions, and stop the motor.
  • Page 303 5.3 Function Code Index by Purpose Maximum Frequency 1 F03 specifies the maximum frequency to limit the output frequency. Specifying the maximum frequency exceeding the rating of the equipment driven by the inverter may cause damage or a dangerous situation. Make sure that the maximum frequency setting matches the equipment rating.
  • Page 304 Normal (linear) V/f pattern V/f pattern with three non-linear points Base Frequency 1 (F04) Set F04 data to the rated frequency printed on the nameplate labeled on the motor. - Data setting range: 25.0 to 500.0 (Hz) Rated Voltage at Base Frequency 1 (F05) Set F05 data to "0"...
  • Page 305 5.3 Function Code Index by Purpose In vector control, current feedback control is performed. In the current feedback control, the current is controlled with the difference between the motor induced voltage and the inverter output voltage. For a proper control, the inverter output voltage should be sufficiently higher than the motor induced voltage.
  • Page 306 F07, F08 Acceleration Time 1, Deceleration Time 1 E10, E12, E14 (Acceleration Time 2, 3 and 4) E11, E13, E15 (Deceleration Time 2, 3 and 4) H07 (Acceleration/Deceleration Pattern) H56 (Deceleration Time for Forced Stop) H54, H55 (Acceleration Time/Deceleration Time, Jogging) H57 to H60 (1st and 2nd S-curve Acceleration/Deceleration Range) F07 specifies the acceleration time, the length of time the frequency increases from 0 Hz to the maximum frequency.
  • Page 307 5.3 Function Code Index by Purpose Acceleration/deceleration time Function code Acceleration/ Switching factor of acceleration/deceleration time deceleration time Refer to the descriptions of E01 to E07.) time time The combinations of ON/OFF states of Acceleration/ the two terminal commands RT2 and deceleration time 1 RT1 offer four choices of acceleration/ deceleration time 1 to 4.
  • Page 308 S-curve acceleration/deceleration To reduce an impact that acceleration/deceleration would make on the machine, the inverter gradually accelerates or decelerates the motor in both the starting and ending zones of acceleration or deceleration. Two types of S-curve acceleration/deceleration rates are available; applying 5% (weak) of the maximum frequency to all of the four inflection zones, and specifying arbitrary rate for each of the four zones with function codes H57 to H60.
  • Page 309 5.3 Function Code Index by Purpose Curvilinear acceleration/deceleration Acceleration/deceleration is linear below the base frequency (constant torque) but it slows down above the base frequency to maintain a certain level of load factor (constant output). This acceleration/deceleration pattern allows the motor to accelerate or decelerate with its maximum performance.
  • Page 310 F10 to F12 Electronic Thermal Overload Protection for Motor 1 (Select motor characteristics, Overload detection level, Thermal time constant) F10 through F12 specify the thermal characteristics of the motor for its electronic thermal overload protection that is used to detect overload conditions of the motor inside the inverter. F10 selects the motor cooling mechanism to specify its characteristics, F11 specifies the overload detection current, and F12 specifies the thermal time constant.
  • Page 311 5.3 Function Code Index by Purpose Nominal Applied Motor and Characteristic Factors when P99 (Motor 1 selection) = 0 or 4 Output frequency for motor Characteristic Nominal Thermal time Reference current characteristic factor factor (%) applied motor constant for setting the thermal (HP) (Factory default) time constant (Imax)
  • Page 312 Example of Thermal Overload Detection Characteristics 5-80...
  • Page 313 5.3 Function Code Index by Purpose Restart Mode after Momentary Power Failure (Mode selection) H13 (Restart time) H14 (Frequency fall rate) H15 (Continuous running level) H16 (Allowable momentary power failure time) H92 and H93 (Continuity of Running, P and I) F14 specifies the action to be taken by the inverter such as trip and restart in the event of a momentary power failure.
  • Page 314 Description Data for F14 Auto search disabled Auto search enabled As soon as the DC link bus voltage drops below the undervoltage detection 5: Restart at the level due to a momentary power failure, the inverter shuts down the output so starting frequency that the motor enters a coast-to-stop state.
  • Page 315 5.3 Function Code Index by Purpose • Under vector control with speed sensor Data for F14 Description 0: Trip immediately As soon as the DC link bus voltage drops below the undervoltage detection level due to a momentary power failure, the inverter issues undervoltage alarm lu and shuts down its output so that the motor enters a coast-to-stop state.
  • Page 316 • When the power is restored, the inverter will wait 2 seconds for input of a run command. However, if the allowable momentary power failure time (H16) has elapsed after the power failure was recognized, the inverter will no longer wait 2 seconds for input of a run command and start operation in the normal starting sequence.
  • Page 317 5.3 Function Code Index by Purpose During a momentary power failure, the motor slows down. After power is restored, the inverter restarts at the frequency just before the momentary power failure. Then, the current limiting function works and the output frequency of the inverter automatically decreases. When the output frequency matches the motor speed, the motor accelerates up to the original output frequency.
  • Page 318 • During auto search, if an overcurrent or overvoltage trip occurs, the inverter restarts the suspended auto search. • Perform auto search at 60 Hz or below. • Note that auto search may not fully provide the performance depending on load conditions, motor parameters, wiring length, and other external factors.
  • Page 319 5.3 Function Code Index by Purpose Restart mode after momentary power failure (Restart time) (H13) H13 specifies the time period from an occurrence of a momentary power failure until the restart of the inverter. (When auto search is enabled, H46 (Auto search delay time 2) applies.) If the inverter starts the motor while motor’s residual voltage is still in a high level, a high inrush current may flow or an overvoltage alarm may occur due to an occurrence of temporary regeneration.
  • Page 320 Restart after momentary power failure (Continuous running level) (H15) Continuity of running (P and I) (H92, H93) • Trip after decelerate-to-stop (F14 = 2) If a momentary power failure occurs when F14 is set to "2" (Trip after decelerate-to-stop), the inverter enters the control sequence of the decelerate-to-stop when the DC link bus voltage drops below the continuous running level specified by H15.
  • Page 321 5.3 Function Code Index by Purpose F15, F16 Frequency Limiter (High and Low) H63 (Low Limiter, Mode selection) Frequency Limiter (High and Low) (F15, F16) F15 and F16 specify the upper and lower limits of the output frequency or reference frequency, respectively.
  • Page 322 Bias (Frequency command 1) Refer to F01. Refer to the description of F01. F20 to F22 DC Braking 1 (Braking starting frequency, Braking level and Braking time) DC Braking (Braking response mode) These function codes specify the DC braking that prevents motor 1 from running by inertia during decelerate-to-stop operation.
  • Page 323 5.3 Function Code Index by Purpose It is also possible to use an external digital input signal as the terminal command DCBRK ("Enable DC braking"). As long as the DCBRK is ON, the inverter performs DC braking, regardless of the braking time specified by F22.
  • Page 324 F23 to F25 Starting Frequency 1, Starting Frequency 1 (Holding time) and Stop Frequency F38 and F39 (Stop Frequency, Detection mode and Holding time) H92 and H93 (Continuity of Running, P and I) d24 (Zero Speed Control) Under V/f control At the startup of an inverter, the initial output frequency is equal to the starting frequency.
  • Page 325 5.3 Function Code Index by Purpose Under vector control with/without speed sensor At the startup, the inverter first starts at the "0" speed and accelerates to the starting frequency according to the specified acceleration time. After holding the starting frequency for the specified period, the inverter again accelerates to the reference speed according to the specified acceleration time.
  • Page 326 Zero Speed Control (d24) (Under vector control with speed sensor only) To enable zero speed control under vector control with speed sensor, it is necessary to set the speed command (frequency command) below the starting and stop frequencies. If the starting and stop frequencies are 0.0 Hz, however, zero speed control is enabled only when the speed command is 0.00 Hz.
  • Page 327 5.3 Function Code Index by Purpose F26, F27 Motor Sound (Carrier frequency and Tone) H98 (Protection/Maintenance Function, Mode selection) Motor Sound (Carrier frequency) (F26) F26 controls the carrier frequency to reduce an audible noise generated by the motor or electromagnetic noise from the inverter itself, and to decrease a leakage current from the main output (secondary) wirings.
  • Page 328 F29 to F31 Analog Output [FM1] and [FM2] (Mode selection, Voltage adjustment, Function) F32, F34, These function codes allow terminals [FM1] and [FM2] to output monitored data such as the output frequency and the output current in an analog DC voltage or current. The magnitude of such analog voltage or current is adjustable.
  • Page 329 5.3 Function Code Index by Purpose Function (F31 and F35) F31 and F35 specify what is output to analog output terminals [FM1] and [FM2], respectively. Data for Function Meter scale F31/F35 [FM1]/[FM2] output (Monitor the following) (Full scale at 100%) Output frequency of the inverter Output frequency 1 (Equivalent to the motor synchronous...
  • Page 330 Load Selection/Auto Torque Boost/Auto Energy Saving Operation 1 F09 (Torque Boost 1) H67 (Auto Energy Saving Operation, Mode selection) F37 specifies V/f pattern, torque boost type, and auto energy saving operation in accordance with the characteristics of the load. Specify the torque boost level with F09 in order to assure sufficient starting torque. Auto energy Data for F37 V/f pattern...
  • Page 331 5.3 Function Code Index by Purpose When the variable torque V/f pattern is selected (F37 = 0 or 3), the output voltage may be low at a low frequency zone, resulting in insufficient output torque, depending on the characteristics of the motor and load. In such a case, it is recommended to increase the output voltage at the low frequency zone using the non-linear V/f pattern.
  • Page 332 Auto torque boost If the auto torque boost is selected, the inverter automatically optimizes the output voltage to fit the motor with its load. Under light load, auto torque boost decreases the output voltage to prevent the motor from over-excitation. Under heavy load, it increases the output voltage to increase the output torque of the motor.
  • Page 333 5.3 Function Code Index by Purpose F38, F39 Stop Frequency (Detection mode and Holding time) Refer to F23. For details about the setting of the stop frequency (detection mode and holding time), refer to the description of F23. F40, F41 Torque Limiter 1-1, 1-2 E16 and E17 (Torque Limiter 2-1, 2-2) H73 (Torque Limiter, Operating conditions)
  • Page 334 Torque limiters 1-1, 1-2, 2-1 and 2-2 (F40, F41, E16 and E17) Data setting range: -300 to 300 (%), 999 (Disable) These function codes specify the operation level at which the torque limiters become activated, as the percentage of the motor rated torque. Function code Name Torque limit feature...
  • Page 335 5.3 Function Code Index by Purpose Switching torque limiters The torque limiters can be switched by the function code setting and the terminal command TL2/TL1 ("Select torque limiter level 2/1") assigned to any of the digital input terminals. To assign the TL2/TL1 as the terminal function, set any of E01 through E07 to "14." If no TL2/TL1 is assigned, torque limiter levels 1-1 and 1-2 (F40 and F41) take effect by default.
  • Page 336 Under vector control with/without speed sensor If the inverter’s output torque exceeds the specified levels of the torque limiters (F40, F41, E16, E17, and E61 to E63), the inverter controls the speed regulator's output (torque command) in speed control or a torque command in torque control in order to limit the motor-generating torque.
  • Page 337 5.3 Function Code Index by Purpose Torque Limiter (Target quadrants) (H75) H75 selects the configuration of target quadrants (Drive/brake, Forward/reverse rotation) in which the specified torque limiter(s) is activated, from "Drive/brake torque limit," "Same torque limit for all four quadrants," and "Upper/lower torque limits" shown in the table below. Data for H75 Target quadrants 0: Drive/brake Torque limiter A applies to driving (both of forward and reverse), and torque limiter B to...
  • Page 338 2: Upper/lower Torque limiter A applies to the upper limit, and torque limiter B to the lower limit. limits Depending upon the polarity of torque limiters A and B, the following patterns are available. Torque limiter A Torque limiter B Pattern 1 Positive Positive...
  • Page 339 5.3 Function Code Index by Purpose Analog torque limit values (E61 to E63) The torque limit values can be specified by analog inputs through terminals [12], [C1], and [V2] (voltage or current). Set E61, E62, and E63 (Terminal [12] Extended Function, Terminal [C1] Extended Function, and Terminal [V2] Extended Function) as listed below.
  • Page 340 Torque limiter (Operating conditions) (H73) H73 specifies whether the torque limiter is enabled or disabled during acceleration/ deceleration and running at constant speed. Data for H73 During accelerating/decelerating During running at constant speed Enable Enable Disable Enable Enable Disable The torque limiter and current limiter are very similar in function. If both are activated concurrently, they may conflict with each other and cause hunting (undesirable oscillation of the system).
  • Page 341 5.3 Function Code Index by Purpose V/f control with slip compensation active Applying any load to an induction motor causes a rotational slip due to the motor characteristics, decreasing the motor rotation. The inverter’s slip compensation function first presumes the slip value of the motor based on the motor torque generated and raises the output frequency to compensate for the decrease in motor rotation.
  • Page 342 Dynamic torque vector control with speed sensor The difference from "V/f control with speed sensor" stated above is to calculate the motor torque matched to the load applied and use it to optimize the voltage and current vector output for getting the maximal torque out of a motor.
  • Page 343 5.3 Function Code Index by Purpose F43, F44 Current Limiter (Mode selection and Level) H12 (Instantaneous Overcurrent Limiting, Mode selection) When the output current of the inverter exceeds the level specified by the current limiter (F44), the inverter automatically manages its output frequency to prevent a stall and limits the output current.
  • Page 344 "Braking resistor (DBR) and braking unit, [ 3 ] Specifications." The values listed in the tables are for standard models and 10% ED models of the braking resistors which Fuji Electric provides. When using a braking resistor of any other manufacturer, confirm the corresponding values with the manufacture and set the function codes accordingly.
  • Page 345 5.3 Function Code Index by Purpose Calculating the discharging capability and allowable average loss of the braking resistor and configuring the function code data When using any non-Fuji braking resistor, inquire of the resistor manufacturer about the resistor rating and then configure the related function codes. The calculation procedures for the discharging capability and allowable average loss of the braking resistor differ depending on the application of the braking load as shown below.
  • Page 346 Allowable average loss (F51) The allowable average loss refers to a tolerance for motor continuous operation, which is obtained based on the %ED (%) and motor rated capacity (HP). Function Data for F51 0.001 to 99.99 0.001 to 99.99 (kW) During deceleration: %ED(%) Motor rated capacity (HP) 0.75...
  • Page 347 5.3 Function Code Index by Purpose The LD/MD-mode inverters are subject to restrictions on the function code data setting range and internal processing as listed below. Function Name LD mode MD mode HD mode Remarks codes DC braking Setting range: F21* Setting range: 0 to 80% (Braking level)

  • Page 348: E Codes (Extension Terminal Functions)

    5.4.2 E codes (Extension terminal functions) E01 to E07 Terminal [X1] to [X7] Functions E98 and E99 (Terminal [FWD] and [REV] Functions) E01 to E07, E98 and E99 assign commands (listed below) to general-purpose, programmable, digital input terminals, [X1] to [X7], [FWD], and [REV]. These function codes can also switch the logic system between normal and negative to define how the inverter logic interprets the ON or OFF state of each terminal.
  • Page 349 5.3 Function Code Index by Purpose Function code data Drive control Related Terminal commands assigned Symbol function Active Active Torque codes control Switch to commercial power (50 Hz) SW50 Switch to commercial power (60 Hz) SW60 1017 UP (Increase output frequency) Frequency command: F01, C30...
  • Page 350 Function code data Drive control Related Terminal commands assigned Symbol function Active Active Torque codes control Count the run time of commercial 1072 CRUN-M1 power-driven motor 1 Count the run time of commercial 1073 CRUN-M2 power-driven motor 2 H44, H94 Count the run time of commercial 1074 CRUN-M3...
  • Page 351 5.3 Function Code Index by Purpose Terminal function assignment and data setting Select multi-frequency (0 to 15 steps) -- SS1, SS2, SS4, and SS8 (Function code data = 0, 1, 2, and 3) The combination of the ON/OFF states of digital input signals SS1, SS2, SS4 and SS8 selects one of 16 different frequency commands defined beforehand by 15 function codes C05 to C19 (Multi-frequency 0 to 15).
  • Page 352 Ready for jogging -- JOG (Function code data = 10) This terminal command is used to jog or inch the motor for positioning a workpiece. Turning this command ON makes the inverter ready for jogging. Refer to C20. Select frequency command 2/1 -- Hz2/Hz1 (Function code data = 11) Turning this terminal command ON and OFF switches the frequency command source between frequency command 1 (F01) and frequency command 2 (C30).
  • Page 353 5.3 Function Code Index by Purpose Operation Schemes • When the motor speed remains almost the same during coast-to-stop: • When the motor speed decreases significantly during coast-to-stop (with the current limiter activated): Function Code Details F codes E01-E09 C codes P codes H codes A codes...
  • Page 354 • Secure more than 0.1 second after turning ON the "Switch to commercial power" signal before turning ON a run command. • Secure more than 0.2 second of an overlapping period with both the "Switch to commercial power" signal and run command being ON. •...
  • Page 355 5.3 Function Code Index by Purpose Example of Sequence Circuit Note 1) Emergency switch Manual switch provided for the event that the motor drive source cannot be switched normally to the commercial power Function due to a serious problem of the inverter Code Details Note 2) When any alarm has occurred inside the inverter, the motor drive source will automatically be switched to the commercial...
  • Page 356 Example of Operation Time Scheme Alternatively, you may use the integrated sequence by which some of the actions above are automatically performed by the inverter itself. For details, refer to the description of ISW50 and ISW60. UP (Increase output frequency) and DOWN (Decrease output frequency) commands -- UP and DOWN (Function code data = 17 and 18) •...
  • Page 357 5.3 Function Code Index by Purpose Enable data change with keypad -- WE-KP (Function code data = 19) Turning the terminal command WE-KP OFF protects function code data from accidentally getting changed by pressing the keys on the keypad. Only when this terminal command is ON, you can change function code data from the keypad. Refer to F00.
  • Page 358 • When process control is performed by the PID processor integrated in the inverter: The terminal command Hz/PID ("Cancel PID control") can switch PID control between enabled (process is to be controlled by the PID processor) and disabled (process is to be controlled by the manual frequency setting).
  • Page 359 5.3 Function Code Index by Purpose Universal DI -- U-DI (Function code data = 25) Using U-DI enables the inverter to monitor digital signals sent from the peripheral equipment via an RS-485 communications link or a fieldbus option by feeding those signals to the digital input terminals.
  • Page 360 Enable integrated sequence to switch to commercial power for 50 Hz and 60 Hz -- ISW50 and ISW60 (Function code data = 40 and 41) With the terminal command ISW50 or ISW60 assigned, the inverter controls the magnetic contactor that switches the motor drive source between the commercial power and the inverter output according to the integrated sequence.
  • Page 361 5.3 Function Code Index by Purpose Circuit Diagram and Configuration Main Circuit Configuration of Control Circuit Summary of Operation Output Input (Status signal and magnetic contactor) Inverter operation SW52-1 SW52-2 SW88 Function ISW50 or ISW60 Run command 52-1 52-2 Code Details F codes E01-E09...
  • Page 362 Timing Scheme Switching from inverter operation to commercial-power operation ISW50/ISW60: ON (1) The inverter output is shut OFF immediately. (Power gate IGBT OFF) (2) The inverter primary circuit SW52-1 and the inverter secondary side SW52-2 are turned OFF immediately. (3) If a run command is present after an elapse of t1 (0.2 sec + time specified by H13), the commercial power circuit SW88 is turned ON .
  • Page 363 5.3 Function Code Index by Purpose Selection of Commercial Power Switching Sequence J22 specifies whether or not to automatically switch to commercial-power operation when an inverter alarm occurs. Data for J22 Sequence (upon occurrence of an alarm) Keep inverter-operation (Stop due to alarm.) Automatically switch to commercial-power operation •...
  • Page 364 2) Sequence with an emergency switching function 3) Sequence with an emergency switching function --Part 2 (Automatic switching by the alarm output issued by the inverter) 5-132...
  • Page 365 5.3 Function Code Index by Purpose Servo-lock command -- LOCK (Function code data = 47) Turning this terminal command ON enables a servo-lock command; turning it OFF disables a servo-lock command. Refer to J97 through J99. Pulse train input -- PIN (available only on terminal [X7]) (Function code data = 48) Pulse train sign -- SIGN (available on terminals except [X7]) (Function code data = 49) Assigning the command PIN to digital input terminal [X7] enables the frequency command by the pulse train input.
  • Page 366 E16, E17 Torque Limiter 2-1, 2-2 (Refer to F40.) Refer to the description of F40. E20 to E23 Terminal [Y1] to [Y4] Functions E24, E27 Terminal [Y5A/C] and [30A/B/C] Functions (Relay output) E20 through E24 and E27 assign output signals (listed on the following pages) to general-purpose, programmable output terminals, [Y1] to [Y4], [Y5A/C] and [30A/B/C].
  • Page 367 5.3 Function Code Index by Purpose Explanations of each function are given in normal logic system "Active ON." Function code data Drive control Related function Functions assigned Symbol codes/ Active Active Torque signals control (data) 1000 Inverter running 1001 Frequency (speed) arrival signal 1002 Frequency (speed) detected E31, E32...
  • Page 368 Function code data Drive control Related function Functions assigned Symbol codes/ Active Active Torque signals control (data) 1044 Motor stopped due to slow flowrate J08, J09 PID-STP under PID control 1045 Low output torque detected U-TL 1046 Torque detected 1 E78 to E81 1047 Torque detected 2...
  • Page 369 5.3 Function Code Index by Purpose Inverter running -- RUN (Function code data = 0) Inverter output on -- RUN2 (Function code data = 35) These output signals tell the external equipment that the inverter is running at a starting frequency or higher.
  • Page 370 Inverter output limiting -- IOL (Function code data = 5) Inverter output limiting with delay -- IOL2 (Function code data = 22) The output signal IOL comes ON when the inverter is limiting the output frequency by activating any of the following actions (minimum width of the output signal: 100 ms). The output signal IOL2 comes ON when any of the following output limiting operation continues for 20 ms or more.
  • Page 371 5.3 Function Code Index by Purpose Select AX terminal function -- AX (Function code data = 15) In response to a run command FWD, this output signal controls the magnetic contactor on the commercial-power supply side. It comes ON when the inverter receives a run command and it goes OFF after the motor decelerates to stop with a stop command received.
  • Page 372 Heat sink overheat early warning -- OH (Function code data = 28) This output signal is used to issue a heat sink overheat early warning that enables you to take a corrective action before an overheat trip 0h1 actually happens. This signal comes ON when the temperature of the heat sink exceeds the "overheat trip temperature minus 5°C (41°F),"...
  • Page 373 5.3 Function Code Index by Purpose PID alarm -- PID-ALM (Function code data = 42) Assigning this output signal enables PID control to output absolute-value alarm or deviation alarm. Refer to J11 through J13. Under PID control -- PID-CTL (Function code data = 43) This output signal comes ON when PID control is enabled ("Cancel PID control"...
  • Page 374 Running forward -- FRUN (Function code data = 52) Running reverse -- RRUN (Function code data = 53) Output signal Assigned data Running forward Running reverse Inverter stopped FRUN RRUN In remote operation -- RMT (Function code data = 54) This output signal comes ON when the inverter switches from local to remote mode.
  • Page 375 5.3 Function Code Index by Purpose PG error detected -- PG-ERR (Function code data = 76) This output signal comes ON when the inverter detects a PG error with the d23 (PG error processing) data being set to "0: Continue to run," in which the inverter does not enter the alarm state.
  • Page 376 Frequency Arrival (Hysteresis width) E30 specifies the detection level (hysteresis width) for the "Frequency (speed) arrival signal" FAR and the "Frequency (speed) arrival signal 3" FAR3. Data assigned to output Operating condition 1 Operating condition 2 Output signal terminal Frequency (speed) FAR always goes OFF when the arrival signal run command is OFF or the...
  • Page 377 5.3 Function Code Index by Purpose E31, E32 Frequency Detection (Level and Hysteresis width) E36 (Frequency Detection 2, Level) E54 (Frequency Detection 3, Level) When the output frequency (estimated/detected speed) exceeds the frequency detection level specified by E31, the "Frequency (speed) detected signal" comes ON; when it drops below the "Frequency detection level minus Hysteresis width specified by E32,"...
  • Page 378 Motor overload early warning signal -- OL The OL signal is used to detect a symptom of an overload condition (alarm code 0l1 ) of the motor so that the user can take an appropriate action before the alarm actually happens. The OL signal turns ON when the inverter output current exceeds the level specified by E34.
  • Page 379 5.3 Function Code Index by Purpose E40, E41 PID Display Coefficient A, B These function codes specify PID display coefficients A and B to convert a PID command (process command or dancer position command) and its feedback into easy-to-understand physical quantities to display. - Data setting range: -999 to 0.00 to 9990 for PID display coefficients A and B Display coefficients for PID process command and its feedback (J01 = 1 or 2) E40 specifies coefficient A that determines the display value at 100% of the PID process...
  • Page 380 Display coefficients for PID dancer position command and its feedback (J01 = 3) Under PID dancer control, the PID command and its feedback operate within the range 100%, so specify the value at +100% of the PID dancer position command or its feedback as coefficient A with E40, and the value at -100% as coefficient B with E41.
  • Page 381 5.3 Function Code Index by Purpose LED Monitor (Item selection) E48 (LED Monitor, Speed monitor item) E43 specifies the running status item to be monitored and displayed on the LED monitor. Specifying the speed monitor with E43 provides a choice of speed-monitoring formats selectable with E48 (LED Monitor).
  • Page 382 LED Monitor (Display when stopped) E44 specifies whether the specified value (data = 0) or the output value (data = 1) to be displayed on the LED monitor of the keypad when the inverter is stopped. The monitored item depends on the E48 (LED monitor, Speed monitor item) setting as shown below.
  • Page 383 5.3 Function Code Index by Purpose Full-scale values on bar charts Item displayed Full scale Output frequency Maximum frequency Output current Inverter rated current 200% Calculated torque Motor rated torque 200% LCD Monitor ( Language selection E46 specifies the language to display on the keypad (TP-G1W-J1) as follows: Data for E46 Language Japanese...
  • Page 384 Display Coefficient for Input Watt-hour Data E51 specifies a display coefficient (multiplication factor) for displaying the input watt-hour data ( 5_10 ) in a part of maintenance information on the keypad. Input watt-hour data = Display coefficient (E51 data) Input watt-hour (kWh) - Data setting range: 0.000 (cancel/reset) 0.001 to 9999 Setting E51 data to 0.000 clears the input watt-hour and its data to "0."...
  • Page 385 5.3 Function Code Index by Purpose monitor Menu # Menu Main functions shows: Displays only function codes that have been changed "rep "Data Checking" from their factory defaults. You can refer to or change those function code data. "Drive Displays the running information required for #ope Monitoring"...
  • Page 386 Data for E61, Input assigned to [12], Description E62, or E63 [C1] and [V2]: This is used when analog inputs are used as torque Analog torque limit limiters. value A Refer to F40 (Torque Limiter 1-1).) This is used when analog inputs are used as torque Analog torque limit limiters.
  • Page 387 5.3 Function Code Index by Purpose Reference Loss Detection (Continuous running frequency) When the analog frequency command (setting through terminal [12], [C1], or [V2]) has dropped below 10% of the reference frequency within 400 ms, the inverter presumes that the analog frequency command wire has been broken and continues its operation at the frequency determined by the ratio specified by E65 to the reference frequency.
  • Page 388 E78, E79 Torque Detection 1 (Level and Timer) E80, E81 Torque Detection 2/Low Torque Detection (Level and Timer) E78 specifies the operation level and E79 specifies the timer, for the output signal TD1. E80 specifies the operation level and E81 specifies the timer, for the output signal TD2 or U-TL. Operation level Timer Output signal...
  • Page 389 5.3 Function Code Index by Purpose E98, E99 Terminal [FWD] Function Terminal [REV] Function Refer to E01 to E07.) For details, refer to the descriptions of E01 to E07. Function Code Details F codes E codes C01-C19 P codes H codes A codes b codes r codes...

  • Page 390: C Codes (Control Functions)

    5.4.3 C codes (Control functions) C01 to C03 Jump Frequency 1, 2 and 3 Jump Frequency (Hysteresis width) These function codes enable the inverter to jump over three different points on the output frequency in order to skip resonance caused by the motor speed and natural frequency of the driven machinery (load).
  • Page 391 5.3 Function Code Index by Purpose Multi-frequency 1 to 15 (C05 through C19) - Data setting range: 0.00 to 500.0 (Hz) The combination of SS1, SS2, SS4 and SS8 and the selected frequencies are as follows. Selected frequency command Other than multi-frequency * C05 (multi-frequency 1) C06 (multi-frequency 2) C07 (multi-frequency 3)
  • Page 392 Jogging Frequency H54, H55 (Acceleration/Deceleration Time, Jogging) d09 to d13 (Speed Control (Jogging)) To jog or inch the motor for positioning a workpiece, specify the jogging conditions using the jogging-related function codes (C20, H54, H55, and d09 through d13) beforehand, make the inverter ready for jogging, and then enter a run command.
  • Page 393 5.3 Function Code Index by Purpose Frequency Command 2 (Refer to F01.) For details of frequency command 2, refer to the description of F01. C31 to C35 Analog Input Adjustment for [12] C36 to C39 (Offset, Gain, Filter time constant, Gain base point, Polarity) C41 to C45 Analog Input Adjustment for [C1] (Offset, Gain, Filter time constant, Gain base point)
  • Page 394 Gain To input bipolar analog voltage (0 to ±10 VDC) to terminals [12] and [V2], set C35 and C45 data to "0." Setting C35 and C45 data to "1" enables the voltage range from 0 to +10 VDC and interprets the negative polarity input from 0 to -10 VDC as 0 V. Bias (Frequency command 1) (Bias base point) (Refer to F01.) For details, refer to the description of F01.

  • Page 395: P Codes (Motor 1 Parameters)

    5.3 Function Code Index by Purpose 5.4.4 P codes (Motor 1 parameters) The FRENIC-MEGA drives the motor under "V/f control," "dynamic torque vector control," "V/f control with speed sensor," "dynamic torque vector control with speed sensor," "vector control without speed sensor,"...
  • Page 396 Motor 1 (Auto-tuning) The inverter automatically detects the motor constants and saves them as parameters in its internal memory. Basically, no tuning is required as long as a HP rating motor is used with standard connection with the inverter. There are three types of auto-tuning as listed below. Select appropriate one considering the limitations in your equipment and control mode.
  • Page 397 5.3 Function Code Index by Purpose Functions that are affected by motor parameters in running capability Function Related function codes (representative) Auto torque boost Output torque monitor F31, F35 Load factor monitor F31, F35 Auto energy saving operation Torque limiter Anti-regenerative control (Automatic deceleration) Auto search Slip compensation...
  • Page 398 (undesirable oscillation of the system), so carefully check the operation on the actual machine. P10 determines the response time for slip compensation. Basically, there is no need to modify the default setting. If you need to modify it, consult your Fuji Electric representatives. Function code...
  • Page 399 5.3 Function Code Index by Purpose P13 to P15 Motor 1 (Iron loss factors 1 to 3) P13 to P15 compensates the iron loss caused inside the motor under vector control with speed sensor, in order to improve the torque control accuracy. The combination of P99 (Motor 1 selection) and P02 (Motor 1 rated capacity) data determines the standard value.
  • Page 400 Motor 1 Selection P99 specifies the type of motor 1 to be used. Data for P99 Motor type Motor characteristics 0 (Fuji standard motors, 8-series) Motor characteristics 1 (HP rating motors) Motor characteristics 2 (Fuji motors exclusively designed for vector control) Motor characteristics 3 (Fuji standard motors, 6-series) Other motors To select the motor drive control or to run the inverter with the integrated automatic control...

  • Page 401: H Codes (High Performance Functions)

    5.3 Function Code Index by Purpose 5.4.5 H codes (High performance functions) Data Initialization H03 initializes the current function code data to the factory defaults or initializes the motor parameters. To change the H03 data, it is necessary to press the keys or keys (simultaneous keying).
  • Page 402 When accessing function code P02 with the keypad, take into account that P02 data automatically updates data of function codes P03, P06 through P23, P53 through P56, and H46. Also, when accessing function code A16, b16 or r16, data of related function codes for each are automatically updated.
  • Page 403 5.3 Function Code Index by Purpose <Operation timing scheme> • In the figure below, normal operation restarts in the 4th retry. • In the figure below, the inverter fails to restart normal operation within the number of reset times specified by H04 (in this case, 3 times (H04 = 3)), and issues the alarm output (for any alarm) ALM.
  • Page 404 Cooling Fan ON/OFF Control To prolong the service life of the cooling fan and reduce fan noise during running, the cooling fan stops when the temperature inside the inverter drops below a certain level while the inverter stops. However, since frequent switching of the cooling fan shortens its service life, the cooling fan keeps running for 10 minutes once started.
  • Page 405 5.3 Function Code Index by Purpose Starting Mode (Auto search) H49 (Starting Mode, Auto search delay time 1) H46 (Starting Mode, Auto search delay time 2) H09 specifies the starting mode--whether to enable the auto search for idling motor speed to run the idling motor without stopping it.
  • Page 406 Starting Mode (Auto search delay time 1) (H49) - Data setting range: 0.0 to 10.0 (s) Auto search for the idling motor speed will become unsuccessful if it is done while the motor retains residual voltage. It is, therefore, necessary to leave the motor for an enough time for residual voltage to disappear.
  • Page 407 5.3 Function Code Index by Purpose Deceleration Mode H11 specifies the deceleration mode to be applied when a run command is turned OFF. Data for H11 Function Normal deceleration Coast-to-stop The inverter immediately shuts down its output, so the motor stops according to the inertia of the motor and machinery (load), and their kinetic energy losses.
  • Page 408 Torque Commands Torque commands can be given as analog voltage input (via terminals [12] and [V2]) or analog current input (via terminal [C1]), or via the communications link (communication-dedicated function codes S02 and S03). To use analog voltage/current inputs, it is necessary to set E61 (for terminal [12]), E62 (for terminal [C1]), or E63 (for terminal [V2]) data to "10"...
  • Page 409 5.3 Function Code Index by Purpose Torque Control (Speed limits 1 and 2) (d32, d33) Torque control controls the motor-generating torque, not the speed. The speed is determined secondarily by torque of the load, inertia of the machinery, and other factors. To prevent a dangerous situation, therefore, the speed limit functions (d32 and d33) are provided inside the inverter.
  • Page 410 H26, H27 Thermistor (for motor) (Mode selection and Level) These function codes specify the PTC (Positive Temperature Coefficient)/NTC (Negative Temperature Coefficient) thermistor embedded in the motor. The thermistor is used to protect the motor from overheating or output an alarm signal. Thermistor (for motor) (Mode selection) (H26) H26 selects the function operation mode (protection or alarm) for the PTC/NTC thermistor as shown below.
  • Page 411 5.3 Function Code Index by Purpose Suppose that the internal resistance of the PTC thermistor at the alarm temperature is Rp, the detection level (voltage) V is calculated by the expression below. Set the result V to function code H27. 10.5 ×...
  • Page 412 To use droop control, be sure to auto-tune the inverter for the motor beforehand. Under V/f control, to prevent the inverter from tripping even at an abrupt change in load, droop control applies the acceleration/deceleration time to the frequency obtained as a result of droop control.
  • Page 413 5.3 Function Code Index by Purpose Command sources specified by H30 (Communications link function, Mode selection) Data for H30 Frequency command Run command Inverter itself (F01/C30) Inverter itself (F02) RS-485 communications link (port 1) Inverter itself (F02) Inverter itself (F01/C30) RS-485 communications link (port 1) RS-485 communications link (port 1) RS-485 communications link (port 1)
  • Page 414 H42, H43 Capacitance of DC Link Bus Capacitor, Cumulative Run Time of Cooling Fan Cumulative Run Time of Capacitors on Printed Circuit Boards H47 (Initial Capacitance of DC Link Bus Capacitor H98 (Protection/Maintenance Function) Life prediction function The inverter has the life prediction function for some parts which measures the discharging time or counts the voltage applied time, etc.
  • Page 415 5.3 Function Code Index by Purpose Capacitance measurement of DC link bus capacitor (H42) Calculating the capacitance of DC link bus capacitor - The discharging time of the DC link bus capacitor depends largely on the inverter's internal load conditions, e.g. options attached or ON/OFF of digital I/O signals. If actual load conditions are so different from the ones at which the initial/reference capacitance is measured that the measurement result falls out of the accuracy level required, then the inverter does not perform measuring.
  • Page 416 Ensure that transistor output signals ([Y1] to [Y4]) and relay output signals ([Y5A] - [Y5C], and [30A/B/C]) will not be turned ON. Disable the RS-485 communications link. If negative logic is specified for the transistor output and relay output signals, they are considered ON when the inverter is not running.
  • Page 417 5.3 Function Code Index by Purpose 5) Turn OFF the inverter, and the following operations are automatically performed. The inverter measures the discharging time of the DC link bus capacitor and saves the result in function code H47 (Initial capacitance of DC link bus capacitor). The conditions under which the measurement has been conducted will be automatically collected and saved.
  • Page 418 Mock Alarm H97 (Clear Alarm Data) H45 causes the inverter to generate a mock alarm in order to check whether external sequences function correctly at the time of machine setup. Setting the H45 data to "1" displays mock alarm err on the LED monitor. It also issues alarm output (for any alarm) ALM (if assigned to a digital output terminal by any of E20 to E24 and E27).
  • Page 419 5.3 Function Code Index by Purpose Low Limiter (Mode selection) Refer to F15.) For details, refer to the description of F15. Low Limiter (Lower limiting frequency) H64 specifies the lower limit of frequency to be applied when the current limiter, torque limiter, automatic deceleration (anti-regenerative control), or overload prevention control is activated.
  • Page 420 In addition, during deceleration triggered by turning the run command OFF, anti-regenerative control increases the output frequency so that the inverter may not stop the load depending on the load state (huge moment of inertia, for example). To avoid that, H69 provides a choice of cancellation of anti-regenerative control to apply when three times the specified deceleration time is elapsed, thus decelerating the motor forcibly.
  • Page 421 5.3 Function Code Index by Purpose Overload prevention control -- OLP (E20 to E24 and E27, data = 36) This output signal comes ON when the overload prevention control is activated and the output frequency changed. In equipment where a decrease in the output frequency does not lead to a decrease in the load, the overload prevention control is of no use and should not be enabled.
  • Page 422 Service Life of DC Link Bus Capacitor (Remaining time) H77 displays the remaining time before the service life of DC link bus capacitor expires. At the time of a printed circuit board replacement, transfer the service life data of the DC link bus capacitor to the new board.
  • Page 423 5.3 Function Code Index by Purpose Count the run time of commercial power-driven motor 1, 2, 3 and 4 -- CRUN-M1, CRUN-M2, CRUN-M3 and CRUN-M4 (E01 to E07, data = 72, 73, 74 and 75) Even when a motor is driven by commercial power, not by the inverter, it is possible to count the cumulative motor run time 1 to 4 (H94, A51, b51, r51) by detecting the ON/OFF state of the auxiliary contact of the magnetic contactor for switching to the commercial power line.
  • Page 424 H81, H82 Light Alarm Selection 1 and 2 If the inverter detects a minor abnormal state "light alarm," it can continue the current operation without tripping while displaying the "light alarm" indication l-al on the LED monitor. In addition to the indication l-al , the inverter displays the "L-ALARM" (blinking) on the LCD monitor and outputs the "light alarm"...
  • Page 425 5.3 Function Code Index by Purpose Code Name Description Inverter life Number of startups reached the specified level. (Number of startups) In synchronous operation, a positioning deviation has become excessive. (See the PG Interface Card instruction manual.) Positioning control error Note: Even if a positioning control error is regarded as a light alarm with H82, the error that occurred when the inverter was servo-locked does not cause a light alarm...
  • Page 426 Table 5.3 Display of Light Alarm Factor (Example) Light alarm factors "RS-485 communications error (COM port 2)," "RS-485 communications error (COM port 1)," "Option communications error," "Overload of motor 1" and "Heat sink overheat" are selected by H81. LED No. LED4 LED3 LED2...
  • Page 427 5.3 Function Code Index by Purpose H84, H85 Pre-excitation (Initial level, Time) A motor generates torque with magnetic flux and torque current. Lag elements of the rising edge of magnetic flux causes a phenomenon in which enough torque is not generated at the moment of the motor start.
  • Page 428 Pre-excitation--EXITE (E01 to E07, data = 32) Turning this input signal ON starts pre-excitation. After the delay time for establishing magnetic flux has elapsed, a run command is inputted. Inputting the run command terminates pre-excitation and starts acceleration. Use an external sequence to control the time for establishing magnetic flux. Under V/f control (including auto torque boost and torque vector), pre-excitation is disabled, so use DC braking or hold the starting frequency instead.
  • Page 429 5.3 Function Code Index by Purpose H92, H93 Continuity of Running (P and I) Refer to F14.) Refer to the description of F14. Cumulative Motor Run Time 1 Refer to H78.) Refer to the description of H78. DC Braking (Braking response mode) (Refer to F20 through F22.) Refer to the descriptions of F20 through F22.
  • Page 430 Clear Alarm Data H45 (Mock Alarm) H97 clears alarm data (alarm history and relevant information) stored in the inverter. To clear alarm data, simultaneous keying of " key + key" is required. Data for H97 Function Disable Enable (Setting "1" clears alarm data and then returns to "0.") Protection/Maintenance Function (Mode selection) H98 specifies whether to enable or disable automatic lowering of carrier frequency, input phase loss protection, output phase loss protection, judgment threshold on the life of DC link bus...
  • Page 431 5.3 Function Code Index by Purpose Judgment on the life of DC link bus capacitor (Bit 4) Whether the DC link bus capacitor has reached its life is judged by measuring the discharging time after power OFF. The discharging time is determined by the capacitance of the DC link bus capacitor and the load inside the inverter.
  • Page 432 To set data of function code H98, assign the setting of each function to each bit and then convert the 8-bit binary to the decimal number. Refer to the assignment of each function to each bit and a conversion example below. Function Bit data = 0 Bit data = 1...

  • Page 433: A Codes (Motor 2 Parameters) B Codes (Motor 3 Parameters) R Codes (Motor 4 Parameters)

    5.3 Function Code Index by Purpose 5.4.6 A codes (Motor 2 parameters) b codes (Motor 3 parameters) r codes (Motor 4 parameters) The FRENIC-MEGA can switch control parameters even when it is running so that a single inverter can drive four motors by switching them or turn the energy saving operation ON or OFF for the setup change (e.g., gear switching) that causes the moment of inertia of the machinery to change.
  • Page 434 If A42, b42 or r42 is set to "0" (Motor (Switch to the 2nd, 3rd or 4th motor)), the combination of M2, M3 and M4 switches the motor to any of the 2nd to 4th motors and also switches the function code group enabled to the one corresponding to the selected motor, as listed in Table 5.5.
  • Page 435 5.3 Function Code Index by Purpose Table 5.5 Function Codes to be Switched (continued) Function code Object of Name parameter motor motor motor motor switching (Magnetic saturation factor 5) (Magnetic saturation extension factor "a") (Magnetic saturation extension factor "b") (Magnetic saturation extension factor "c") Motor selection Slip compensation (Operating conditions) H68...
  • Page 436 ASR Switching Time (d25) Parameter switching is possible even during operation. For example, speed control P (Gain) and I (Integral time) listed in Table 5.5 can be switched. Switching these parameters during operation may cause an abrupt change of torque and result in a mechanical shock, depending on the driving condition of the load.

  • Page 437: J Codes (Application Functions 1)

    5.3 Function Code Index by Purpose 5.4.7 J codes (Application functions 1) PID Control (Mode selection) Under PID control, the inverter detects the state of a control target object with a sensor or the similar device and compares it with the commanded value (e.g., temperature control command). If there is any deviation between them, PID control operates to minimize it.
  • Page 438 Using J01 enables switching between normal and inverse operations against the PID process control output, so you can specify an increase/decrease of the motor rotating speed to the difference (error component) between the commanded (input) and feedback amounts, making it possible to apply the inverter to air conditioners.
  • Page 439 5.3 Function Code Index by Purpose PID Control (Remote command SV) J02 sets a command source that specifies the command value (SV) under PID control. Data Refer Function for J02 keys on keypad [ 1 ] Specify the PID command using the keys on the keypad.
  • Page 440 On the LED monitor, the decimal point of the lowest digit is used to characterize what is displayed. The decimal point of the lowest digit blinks when a PID command is displayed; the decimal point lights when a PID feedback amount is displayed. (5) To change the PID command, press the key again.
  • Page 441 5.3 Function Code Index by Purpose [ 2 ] PID command by analog inputs (J02 = 1) When any analog input (voltage input to terminals [12] and [V2], or current input to terminal [C1]) for PID command 1 (J02 = 1) is used, it is possible to arbitrary specify the PID command by multiplying the gain and adding the bias.
  • Page 442 (Example) Mapping the range of 1 through 5 V at terminal [12] to 0 through 100% [ 3 ] PID command with UP/DOWN control (J02 = 3) When the UP/DOWN control is selected as a PID command, turning the terminal command UP or DOWN ON causes the PID command to change within the range from 0 to 100%.
  • Page 443 5.3 Function Code Index by Purpose Selecting Feedback Terminals For feedback control, determine the connection terminal according to the type of the sensor output. • If the sensor is a current output type, use the current input terminal [C1] of the inverter. •...
  • Page 444 (Example 2) When the output level of the external sensor is 0 to 10 VDC: • Use terminal [12] designed for voltage input. • When the external sensor's output is of unipolar, the inverter controls the speed within the range of 0 to 100%.
  • Page 445 5.3 Function Code Index by Purpose P (Proportional) action An operation in which the MV (manipulated value: output frequency) is proportional to the deviation is called P action, which outputs the MV in proportion to deviation. However, the P action alone cannot eliminate deviation. Gain is data that determines the system response level against the deviation in P action.
  • Page 446 D (Differential) action An operation in which the MV (manipulated value: output frequency) is proportional to the differential value of the deviation is called D action, which outputs the MV that differentiates the deviation. D action makes the inverter quickly react to a rapid change of deviation. The effectiveness of D action is expressed by differential time as parameter, that is J05 data.
  • Page 447 5.3 Function Code Index by Purpose Refining the system response waveforms is shown below. 1) Suppressing overshoot Increase the data of J04 (Integral time) and decrease that of J05 (Differential time.) 2) Quick stabilizing (moderate overshoot allowable) Decrease the data of J03 (Gain) and increase that of J05 (Differential time). 3) Suppressing oscillation whose period is longer than the integral time specified by J04 Increase the data of J04 (Integral time).
  • Page 448 Feedback filter (J06) J06 specifies the time constant of the filter for feedback signals under PID control. - Data setting range: 0.0 to 900.0 (s) - This setting is used to stabilize the PID control loop. Setting too long a time constant makes the system response slow.
  • Page 449 5.3 Function Code Index by Purpose For the slow flowrate stopping function, see the chart below. Pressurization before slow flowrate stopping (J08 and J09) Specifying J08 (Pressurization starting frequency) and J09 (Pressurizing time) enables pressurization control when the frequency drops below the level specified by J15 (Stop frequency for slow flowrate) for the period specified by J16.
  • Page 450 PID Control (Anti reset windup) J10 suppresses overshoot under control using a PID processor. As long as the deviation between the PID command and its feedback is out of the preset range, the integrator holds its value and does not perform integration operation. - Data setting range: 0 to 200 (%) J11 to J13 PID Control (Select alarm output, Upper level alarm (AH) and...
  • Page 451 5.3 Function Code Index by Purpose Hold: During the power-on sequence, the alarm output is kept OFF (disabled) even when the monitored quantity is within the alarm range. Once it goes out of the alarm range, and comes into the alarm range again, the alarm is enabled. Latch: Once the monitored quantity comes into the alarm range and the alarm is turned ON, the alarm will remain ON even if it goes out of the alarm range.
  • Page 452 J18, J19 PID Control (Upper limit of PID process output, Lower limit of PID process output) The upper and lower limiters can be specified to the PID output, exclusively used for PID control. The settings are ignored when PID cancel is enabled and the inverter is operated at the reference frequency previously specified.
  • Page 453 5.3 Function Code Index by Purpose PID Control (Speed command filter) Not used. PID Control (Dancer reference position) J57 specifies the dancer reference position in the range of -100% to +100% for dancer control. This function code is enabled when J02 = 0 (Keypad). The PID command can also be modified with the keys and the modified command value is saved as J75 data.
  • Page 454 J68 to J70 Brake Signal (Brake-OFF current, Brake-OFF frequency/speed and Brake-OFF timer) J71, J72 Brake Signal (Brake-ON frequency/speed and Brake-ON timer) J95, J96 Brake Signal (Brake-OFF torque and Speed condition selection) These function codes are for the brake releasing/activating signals of vertical carrier machines. It is possible to set the conditions of the brake releasing/activating signals (current, frequency or torque) so that a hoisted load does not fall down at the start or stop of the operation, or so that the load applied to the brake is reduced.
  • Page 455 5.3 Function Code Index by Purpose Function Name Data setting range Remarks code Brake-ON 0.0 to 25.0 Hz frequency/speed Brake-ON timer 0.0 to 5.0 s Criteria of speed condition for Specifies the criteria of speed to be Speed condition brake-ON (Bit 0) used for brake-ON condition.
  • Page 456 Operation time chart under V/f control Operation time chart under vector control without speed sensor Operation time chart under vector control with speed sensor • If zero speed control is enabled under vector control with speed sensor, set J95 (Brake-OFF torque) at 0%. •...
  • Page 457 5.3 Function Code Index by Purpose J97 to J99 Servo-lock (Gain, Completion timer, Completion range) Servo-lock This function servo-locks the inverter to hold the motor within the positioning completion range specified by J99 for the period specified by J98 even if an external force applies to the load. When the inverter is servo-locked, it keeps the output frequency low;...
  • Page 458 Servo-lock (Gain) (J97) J97 specifies the gain of the servo-lock positioning device to adjust the stop behavior and shaft holding torque. Small Large Stop behavior Response slow, but smooth Response quick, but hunting large Shaft holding torque Small Large Monitor for servo-lock control Monitor item LCD monitor Function code...

  • Page 459: D Codes (Application Functions 2)

    5.3 Function Code Index by Purpose 5.4.8 d codes (Application functions 2) d01 to d04 Speed Control 1 (Speed command filter, Speed detection filter, P (Gain) and I (Integral time)) Speed Control 1 (Output filter) These function codes control the speed control sequence for normal operations. Block diagram of the speed control sequence Speed command filter (d01) d01 specifies a time constant determining the first order delay of the speed command filter.
  • Page 460 P gain Definition of "P gain = 1.0" is that the torque command is 100% (100% torque output of each inverter capacity) when the speed deviation (reference speed – detected speed) is 100% (equivalent to the maximum speed). Determine the P gain according to moment of inertia of machinery loaded to the motor output shaft.
  • Page 461 5.3 Function Code Index by Purpose The following four types of notch filters can be specified. Function Data setting Default Name Unit code range setting Speed control 1 1 to 200 (Notch filter resonance frequency) Notch filter 1 Speed control 1 0 to 20 0 (Disable) (Notch filter attenuation level)
  • Page 462 d14 to d17 Feedback Input (Pulse input format, Encoder pulse resolution, Pulse count factor 1 and Pulse count factor 2) These function codes specify the speed feedback input under vector control with speed sensor. Feedback Input, Pulse input format (d14) d14 specifies the speed feedback input format.
  • Page 463 5.3 Function Code Index by Purpose Feedback Input, Pulse count factor 1 (d16) and Pulse count factor 2 (d17) d16 and d17 specify the factors to convert the speed feedback input pulse rate into the motor shaft speed (min - Data setting range: 1 to 9999 Specify the data according to the transmission ratios of the pulley and gear train as shown below.
  • Page 464 d21, d22 Speed Agreement/PG Error (Hysteresis width and Detection timer) PG Error Processing These function codes specify the detection levels of the speed agreement signal DSAG and PG error detected signal PG-ERR. Speed agreement signal DSAG (E20 to E24 and E27, data = 71) Speed Agreement/PG Error (Hysteresis width (d21) and Detection timer (d22)) - Data setting range: (d21) 0.0 to 50.0 (%), 100 (%) at the maximum speed (d22) 0.00 to 10.00 (s)
  • Page 465 5.3 Function Code Index by Purpose Zero Speed Control (Refer to F23.) Refer to the description of F23. ASR Switching Time (Refer to A42.) Refer to the description of A42. d32, d33 Torque control (Speed limits 1 and 2) If a regenerative load (which is not generated usually) is generated under droop control or function codes are incorrectly configured, then the motor may rotate at an unintended high speed.
  • Page 466 Machinery configuration of winder system and function code settings Shown below is a machinery configuration of a winder system for which it is necessary to configure the function codes as listed below. Winder (The radius of the take-up roll increases as the roll rotates.) Radius of take-up roll (r Speed ｖ...
  • Page 467 5.3 Function Code Index by Purpose Setting with analog inputs To specify a peripheral speed (line speed) using analog inputs, set an analog input (0 to 100%) based on the following equation. b 100 Analog input (%) = r 1 a fmax Where Peripheral speed (Line speed) in m/min...
  • Page 468 Hold the constant peripheral speed control frequency in the memory -- LSC-HLD (Function code E01 to E07, data = 71) If LSC/HLD is ON under constant peripheral speed control, stopping the inverter (including an occurrence of an alarm and a coast-to-stop command) or turning OFF Hz/LSC saves the current frequency command compensating for a take-up roll getting bigger, in the memory.

  • Page 469: U Codes (Application Functions 3)

    5.3 Function Code Index by Purpose 5.4.9 U codes (Application functions 3) Customizable Logic (Mode selection) U01 to U50 Customizable Logic: Step 1 to 10 (Setting) U71 to U75 Customizable Logic Output Signal 1 to 5 (Output selection) U81 to U85 Customizable Logic Output Signal 1 to 5 (Function selection) Customizable Logic Timer Monitor (Step selection) The customizable logic function allows the user to form a logic circuit for digital input/output...
  • Page 470 Customizable Logic (Mode selection) (U00) U00 specifies whether to enable the sequence configured with the customizable logic function or disable it to run the inverter only via its input terminals and others. Data for U00 Function Disable Enable (Customizable logic operation) Customizable Logic (Setting) (U01 to U50) In a customizable logic, one step is composed of the components shown in the following block diagram.
  • Page 471 5.3 Function Code Index by Purpose Data Selectable Signals 2009 (3009) Output of step 9 SO09 2010 (3010) Output of step 10 SO10 4001 (5001) Terminal [X1] input signal 4002 (5002) Terminal [X2] input signal 4003 (5003) Terminal [X3] input signal 4004 (5004) Terminal [X4] input signal 4005 (5005) Terminal [X5] input signal 4006 (5006) Terminal [X6] input signal...
  • Page 472 Data Function Description Falling edge detector + Falling edge detector with 1 input and 1 output, plus General-purpose timer general-purpose timer. This detects the falling edge of an input signal and outputs the ON signal for 2 ms. Rising & falling edges detector Rising and falling edges detector with 1 input and 1 output, + General-purpose timer plus general-purpose timer.
  • Page 473 5.3 Function Code Index by Purpose (6) Reset priority flip-flop General-purpose timer Previous Input 1 Input 2 Output Remarks Flip-flop output Input 1 Output Hold previous value Input 2 Reset priority － － － (7) Rising edge detector (8) Falling edge detector (9) Rising &...
  • Page 474 General-purpose timer (U04, etc.) The table below lists the general-purpose timers available. Data Function Description No timer On-delay timer Turning an input signal ON starts the on-delay timer. When the period specified by the timer has elapsed, an output signal turns ON. Turning the input signal OFF turns the output signal OFF.
  • Page 475 5.3 Function Code Index by Purpose Time setting (U05, etc.) U05 and other related function codes specify the general-purpose timer period or the increment/decrement counter value. Data Function Description Timer period The period is specified by seconds. 0.00 to 600.00 The specified value is multiplied by 100 times.
  • Page 476 Function Default Name Data setting range code setting Customizable logic output signal 1 0 to 100, 1000 to 1081 (Function selection) Same as data of E98/E99, except the Customizable logic output signal 2 following. (Function selection) 19 (1019): Enable data change with Customizable logic output signal 3 keypad (data can be modified) (Function selection)
  • Page 477 5.3 Function Code Index by Purpose Monitoring Related function code and Monitored by: Monitored item LED monitor display Communications link X90 Customizable logic (Timer monitor) Timer or counter value specified by U91 (dedicated to monitoring) Cancel customizable logic -- CLC (E01 to E07, data = 80) This terminal command disables the customizable logic temporarily.
  • Page 478 Customizable logic configuration samples Configuration sample 1: Switch two or more signals using a single switch When switching between M2 (Select motor 2) and TL2/TL1 (Select torque limiter level 2/1) with a single switch, using a customizable logic instead of a conventional external circuit reduces the number of the required general-purpose input terminals to one as shown below.
  • Page 479 5.3 Function Code Index by Purpose Configuration sample 2: Put two or more output signals into one When putting two or more output signals into one, using a customizable logic instead of a conventional external circuit reduces the number of the required general-purpose output terminals and eliminates external relays as shown below.
  • Page 480 Configuration sample 3: One-shot operation When starting the inverter by short-circuiting the SW-FWD or SW-REV switch and stopping it by short-circuiting the SW-STOP switch (which are functionally equivalent to depression of the RUN and STOP keys on the keypad, respectively), using a customizable logic instead of a conventional external circuit simplifies the external circuit as shown below.
  • Page 481 5.3 Function Code Index by Purpose Setting Function Code Function Remarks Data U11 Customizable Logic: (Input 1) 4010 Terminal [FWD] input Step 3 signal, FWD (Input 2) 4001 Terminal [X1] input signal, X1 (Logic circuit) ORing + Operation General-purpose timer selection U16 Customizable Logic: (Input 1)
  • Page 482 Configuration sample 4: Pattern operation Driving the motor while switching the reference frequency and acceleration/deceleration time at specified time intervals is called "Pattern operation." Given below is a pattern operation sample chart. Reference frequency Multi-frequency 1 Multi-frequency 2 Multi-frequency 3 Accel/decel time 1 Accel/decel time 2 Accel/decel time 3...
  • Page 483 5.3 Function Code Index by Purpose Function Code Details F codes E codes C codes P codes H codes A codes b codes r codes J codes d codes Operation Chart of U00-U91 y codes Customizable Logic Steps 1 to 9 for "A Single Cycle of Pattern Operation and Stop" 5-251...
  • Page 484 To configure the above customizable logic, set function codes as listed below. The "Type of timer" and "Time setting" require no modification unless otherwise specified. Setting Function Code Function Remarks Data E98 Terminal [FWD] Function No function assigned, NONE U00 Customizable Logic (Mode selection) Enable U01 Customizable Logic: (Input 1)
  • Page 485 5.3 Function Code Index by Purpose Setting Function Code Function Remarks Data U41 Customizable Logic: (Input 1) 4010 Terminal [FWD] input Step 9 signal, FWD (Input 2) 2008 Output of step 8, SO08 (Logic circuit) ANDing + General-purpose timer U71 Customizable Logic (Output Output of step 9, SO09 FWD Output Signal 1...
  • Page 486 (2) Repeating of pattern operation This sample carries out the specified pattern operation repeatedly and stops the inverter output upon receipt of a stop command. Output frequency TE01 time TE02 time TE03 time TE04 time TE01 time Timing Chart of "Repeating of Pattern Operation" Customizable Logic Configuration for "Repeating of Pattern Operation"...
  • Page 487 5.3 Function Code Index by Purpose To configure the above customizable logic, set function codes as listed below. The "Type of timer" and "Time setting" require no modification unless otherwise specified. Setting Function Code Function Remarks Data E98 Terminal [FWD] Function Run forward, FWD U00 Customizable Logic (Mode selection) Enable...
  • Page 488 Setting Function Code Function Remarks Data U31 Customizable Logic: (Input 1) 2004 Output of step 4, SO04 Step 7 (Input 2) 2005 Output of step 5, SO05 (Logic circuit) ORing + General-purpose timer U71 Customizable Logic (Output Output of step 6, SO06 SS1 Output Signal 1 selection) command...
  • Page 489 5.3 Function Code Index by Purpose (3) A single cycle of pattern operation and continuation of running This sample carries out a cycle of the specified pattern operation and continues to run. Output frequency TE01 time TE02 time TE03 time TE04 time Timing Chart of "A Single Cycle of Pattern Operation and Continuation of Running"...
  • Page 490 To configure the above customizable logic, set function codes as listed below. The "Type of timer" and "Time setting" require no modification unless otherwise specified. Setting Function Code Function Remarks Data E98 Terminal [FWD] Function Run forward, FWD U00 Customizable Logic (Mode selection) Enable U01 Customizable Logic: (Input 1)

  • Page 491: Y Codes (Link Functions)

    5.3 Function Code Index by Purpose 5.4.10 y codes (Link functions) y01 to y20 RS-485 Communication 1 and 2 Up to two RS-485 communications ports are available as listed below. Port Route Function code Applicable equipment Port 1 RS-485 communications link y01 through y10 Keypad FRENIC Loader (via the RJ-45 connector prepared for keypad...
  • Page 492 Communications error processing (y02 for port 1 and y12 for port 2) y02 or y12 specifies the error processing to be performed if an RS-485 communications error occurs. RS-485 communications errors include logical errors (e.g., address error, parity error, framing error), transmission protocol error, and physical errors (e.g., no-response error specified by y08 and y18).
  • Page 493 5.3 Function Code Index by Purpose Parity check (y06 for port 1 and y16 for port 2) y06 or y16 specifies the property of the parity bit. Data for y06 Parity and y16 For FRENIC Loader, no setting is required since Loader automatically sets the even parity.
  • Page 494 Protocol selection (y10 for port 1) y10 specifies the communications protocol for Data for y10 Protocol port 1. Modbus RTU protocol For FRENIC Loader (via the RS-485 communications link), only y10 can be used for FRENIC Loader protocol protocol selection. Set the y10 data at "1." Fuji general-purpose inverter protocol Protocol selection (y20 for port 2)
  • Page 495 5.3 Function Code Index by Purpose Loader Link Function (Mode selection) This is a link switching function for FRENIC Loader. Rewriting the data of y99 to enable RS-485 communications from Loader helps Loader send the inverter the frequency and/or run commands. Since the data to be set in the function code of the inverter is automatically set by Loader, no keypad operation is required.

  • Page 497: Block Diagrams For Control Logic

    Chapter 6 BLOCK DIAGRAMS FOR CONTROL LOGIC This chapter provides the main block diagrams for the control logic of the FRENIC-MEGA series of inverters. Contents 6.1 Symbols Used in Block Diagrams and their Meanings ..................6-1 6.2 Drive Frequency Command Block ........................6-2 6.3 Drive Command Block .............................

  • Page 499: Symbols Used In Block Diagrams And Their Meanings

    6.1 Symbols Used in the Block Diagrams and their Meanings FRENIC-MEGA series of inverters is equipped with a number of function codes to match a variety of motor operations required in your system. Refer to Chapter 5 "FUNCTION CODES" for details of the function codes. The function codes have functional relationship each other.

  • Page 500: Drive Frequency Command Block

    6.2 Drive Frequency Command Block Balanceless-bumpless (F01, C30 = 8) LED monitor Key operation on the keypad Selection of normal/inverse 0,1,2 operation Reference frequency Switch Motor speed in min normal/inverse operation Load shaft speed command Reference loss Line speed command detection Display speed in % [12]...
  • Page 501 6.2 Drive Frequency Command Block Select frequency Enable Select Ready for Select local Multi-function command 2/1 communications multi- jogging Frequency (keypad) keypad link via RS-485 frequency Hz2/Hz1 command 1 operation or fieldbus SS1,SS2, SS4,SS8 × Remote/local decision Frequency limiter (High) ×...

  • Page 502: Drive Command Block

    6.3 Drive Command Block Figure 6.2 Drive Command Block...
  • Page 503 6.3 Drive Command Block This page is intentionally left blank.

  • Page 504: Control Block

    6.4 Control Block 6.4.1 V/f control Maximum frequency 1 Base frequency 1 Rotational Starting frequency 1 direction (Holding time) limitation Stop frequency "0" (Holding time) Forward Drive frequency rotation command inhibited ACC/DEC processor Reverse rotation inhibited "-1" Droop control Acceleration/ Calculated torque deceleration pattern...
  • Page 505 6.4 Control Block Power Rectifier DC link bus supply capacitor Cooling fan Motor Cooling fan ON/OFF Output currents Gate drive circuit control (Iu, Iv, Iw) Cooling fan PWM signals ON/OFF control Instantaneous overcurrent limiting (Mode selection) Output current (Iu, Iv, Iw) Alarm Comparator Current limit level...

  • Page 506: V/F Control With Speed Sensor

    6.4.2 V/f control with speed sensor Maximum frequency 1 Base frequency 1 Rotational Starting frequency 1 direction (Holding time) limitation Stop frequency "0" (Holding time) Forward Drive frequency rotation command inhibited ACC/DEC processor Reverse rotation inhibited "-1" Droop control Calculated Acceleration/ torque deceleration pattern...
  • Page 507 6.4 Control Block Power Pulse generator Rectifier DC link bus supply capacitor Cooling fan Motor Cooling fan ON/OFF Output currents Gate drive circuit control (Iu, Iv, Iw) Cooling fan PWM signals ON/OFF control Instantaneous overcurrent limiting (Mode selection) Output current Alarm (Iu, Iv, Iw) Comparator...

  • Page 508: Vector Control With/Without Speed Sensor

    6.4.3 Vector control with/without speed sensor Figure 6.5 (1) Block of Vector Control with/without Speed Sensor 6-10...
  • Page 509 6.4 Control Block Figure 6.5 (2) Block of Vector Control with/without Speed Sensor 6-11...

  • Page 510: Pid Process Control Block

    6.5 PID Process Control Block Balanceless-bumpless (F01, C30 = 8) LED monitor Key operation on the keypad 0,1,2 Reference frequency Motor speed in min Load shaft speed command Frequency command 1 Line speed command Display speed in % [12] × Thermistor Hardware Gain...
  • Page 511 6.5 PID Process Control Block Cancel PID Enable Select control communications multi-frequency Hz/PID link via RS-485 SS1, SS2 or fieldbus Under PID control Inverter running PID-CTL Frequency limiter (High) Manual speed command Communications link function Drive frequency Multi-frequency 1 Bus link function Jump command frequency...

  • Page 512: Pid Dancer Control Block

    6.6 PID Dancer Control Block Figure 6.7 (1) PID Dancer Control Block 6-14...
  • Page 513 6.6 PID Dancer Control Block Enable Select Select frequency communications link command 2/1 multi-frequency Hz2/Hz1 via RS-485 or fieldbus SS1 , SS2 Frequency limiter (High) Primary Communications frequency command Jump Drive frequency link function command frequency Bus link function Loader link function 0,2,6 1,3 to 5,7,8 Frequency...

  • Page 514: Fm1/Fm2 Output Selector

    6.7 FM1/FM2 Output Selector Analog output [FM1] Voltage (Function) Mode selection adjustment Hardware switch SW4 = VO1 Analog output Voltage output Output frequency 1 × [FM1] Output frequency 2 SW4 = IO1 Output current Current output × Output voltage Output torque Load factor Input power PID feedback amount...

  • Page 515: Keypad Functions (Operating With The Keypad

    Chapter 7 KEYPAD FUNCTIONS (OPERATING WITH THE KEYPAD) This chapter describes the names and functions of the keypad and inverter operation using the keypad. The inverter features three operation modes (Running, Programming and Alarm modes) which enable you to run and stop the motor, monitor running status, set function code data, display running information required for maintenance, and display alarm data.

  • Page 517: Led Monitor, Lcd Monitor, And Keys

    7.1 LED Monitor, LCD Monitor, and Keys 7.1 LED Monitor, LCD Monitor, and Keys The keypad allows you to start and stop the motor, view various data including maintenance information and alarm information, configure function codes, monitor I/O signal status, copy data, and calculate the load factor.
  • Page 518 Table 7.1 Overview of Keypad Functions (Continued) Monitors and Item Functions Keys Switches the operation modes of the inverter. Shifts the cursor to the right for entry of a numerical value. Pressing this key after removing the cause of an alarm switches the inverter to Running mode.
  • Page 519 7.1 LED Monitor, LCD Monitor, and Keys Details of Indicator Indexes Type Item Description (information, condition, and status) Output frequency and reference frequency Output current Output voltage Calculated torque, load factor, and speed r/min Preset and actual motor speeds and preset and actual load shaft speeds Unit of number m/min Preset and actual line speeds...

  • Page 520: Overview Of Operation Modes

    7.2 Overview of Operation Modes The FRENIC-MEGA features the following three operation modes. Table 7.2 Operation Modes Mode Description This mode allows you to specify run/stop commands in regular operation. It is also Running Mode possible to monitor the running status in real time. If a light alarm occurs, the l-al * appears on the LED monitor.

  • Page 521: Running Mode

    7.3 Running Mode 7.3 Running Mode When the inverter is turned on, it automatically enters Running mode in which you can (1) Monitor the running status (e.g., output frequency and output current) on the LED monitor (2) Monitor light alarms (3) Configure frequency and PID commands (4) Run or stop the motor (5) Jog (inch) the motor...
  • Page 522 Table 7.3 Items Monitored (Continued) Monitored Items on the Function Example Unit Meaning of Displayed Value Monitor page # LED Monitor code E43 Current output from the inverter in 1"34 Output current 1*25 Input power Input power to the inverter Motor output torque in % Calculated torque (Calculated value)

  • Page 523: Monitoring Light Alarms

    7.3 Running Mode 7.3.2 Monitoring light alarms The FRENIC-MEGA identifies abnormal states in two categories--Alarm and Light alarm. If the former occurs, the inverter immediately trips; if the latter occurs, the l-al appears on the LED monitor and the "L-ALARM" appears blinking in the operation guide area on the LCD monitor, but the inverter continues to run without tripping.
  • Page 524 How to remove the current light alarm After checking the current light alarm, to switch the LED monitor from the l-al indication back to the running status display (e.g., output frequency), press the key in Running mode. If the light alarm has been removed, the "L-ALARM" disappears and the LALM output signal turns OFF. If not (e.g.

  • Page 525: Configuring Frequency And Pid Commands

    7.3 Running Mode 7.3.3 Configuring frequency and PID commands You can set up the desired frequency and PID commands by using keys on the keypad. It is also possible to set up the frequency command as load shaft speed, motor speed or speed (%) by setting function code E48.
  • Page 526 • To input bipolar analog voltage (0 to 10 VDC) to terminals [12] and [V2], set C35 and C45 data to "0." Setting C35 and C45 data to "1" enables the voltage range from 0 to +10 VDC and interprets the negative polarity input from 0 to -10 VDC as 0 V. •...
  • Page 527 7.3 Running Mode Table 7.4 PID Process Command Manually Set with Key and Requirements PID control PID control LED monitor Multi- frequency (Mode selection) (Remote command SV) With SS4, SS8 PID process command by keypad 1 or 2 Other than 0 ON or OFF PID process command Other than 0...
  • Page 528 Settings under PID dancer control To enable the PID dancer control, you need to set the J01 data to "3." Under the PID control, the items that can be specified or checked with keys are different from those under the regular frequency control, depending upon the current LED monitor setting. If the LED monitor is set to the speed monitor (E43 = 0), the item accessible is the primary frequency command;...
  • Page 529 7.3 Running Mode Setting up the primary frequency command with keys under PID dancer control When function code F01 is set to "0" ( keys on keypad) and frequency command 1 is selected as a primary frequency command (when disabling the frequency setting command via communications link, multi-frequency command, and PID control), switching the LED monitor to the speed monitor in Running mode enables you to modify the frequency command with the keys.

  • Page 530: Running Or Stopping The Motor

    7.3.4 Running or stopping the motor By factory default, pressing the key starts running the motor in the forward direction and pressing the key decelerates the motor to a stop. The key is disabled. Running or stopping the motor with the keypad is enabled only in Running and Programming modes.
  • Page 531 7.3 Running Mode (2) When function code E45 (LCD monitor item selection) is set at "1" The LCD monitor displays the output frequency, output current, and calculated torque in a bar chart. (The upper indicators show the unit of values displayed on the LED monitor as detailed in Section 7.3.2.

  • Page 532: Jogging (Inching) The Motor

    7.3.5 Jogging (inching) the motor To start jogging operation, perform the following procedure. (1) Making the inverter ready for jogging 1) Switch the inverter to Running mode (see Section 7.2). 2) Press the " keys" simultaneously (when the run command source is "Keypad" (F02 = 0, , or 3).

  • Page 533: Switching Between Remote And Local Modes

    7.3 Running Mode 7.3.6 Switching between remote and local modes The inverter is switchable between remote and local modes. In remote mode that applies to ordinary operation, the inverter is driven under the control of the data settings held in it, whereas in local mode that applies to maintenance operation, it is separated from the control system and is driven manually under the control of the keypad.

  • Page 534: External Run/Frequency Command

    7.3.7 External run/frequency command By factory default, run and frequency commands are sourced from the keypad. This section provides other external command source samples--an external frequency command potentiometer (variable resistor) as a frequency command source and external run switches as run forward/reverse command sources. Set up those external sources using the following procedure.

  • Page 535: Programming Mode

    7.4 Programming Mode 7.4 Programming Mode Programming mode provides you with these functions--setting and checking function code data, monitoring maintenance information and checking input/output (I/O) signal status. These functions can be easily selected with a menu-driven system. Table 7.9 lists menus available in Programming mode. When the inverter enters Programming mode from the second time on, the menu selected last in Programming mode will be displayed.

  • Page 536: Setting Up Function Codes Quickly Using Quick Setup -- Menu #0 "Quick Setup

    Figure 7.8 shows the transitions between menus in Programming mode. Figure 7.8 Menu Transition in Programming Mode If no key is pressed for approx. 5 minutes, the inverter automatically goes back to Running mode and turns the backlight OFF. 7.4.1 Setting up function codes quickly using Quick Setup -- Menu #0 "Quick Setup"...

  • Page 537: Setting Up Function Codes -- Menu #1 "Data Setting

    7.4 Programming Mode 7.4.2 Setting up function codes -- Menu #1 "Data Setting" -- Menu #1 "Data Setting" in Programming mode allows you to set up all function codes for making the inverter functions match your needs. Table 7.10 Function Code List Function Code Group Function Description...
  • Page 538 Basic configuration of screens Figure 7.9 shows the LCD screen transition for Menu #1 "Data Setting." A hierarchy exists among those screens that are shifted in the order of "menu screen," "list of function codes," and "function code data modification screens." On the modification screen of the target function code, you can modify or check its data.
  • Page 539 7.4 Programming Mode Basic key operation This section gives a description of the basic key operation, following the example of the data changing flow shown below. This example shows how to change F03 data (maximum frequency) from 58.0 Hz to 58.1 Hz.

  • Page 540: Checking Changed Function Codes -- Menu #2 "Data Checking

    7.4.3 Checking changed function codes -- Menu #2 "Data Checking" -- Menu #2 "Data Checking" in Programming mode allows you to check function codes and their data that has been changed. The function codes whose data has been changed from the factory defaults are marked with an asterisk ( ).

  • Page 541: Monitoring The Running Status -- Menu #3 "Drive Monitoring

    7.4 Programming Mode 7.4.4 Monitoring the running status -- Menu #3 "Drive Monitoring" -- Menu #3 "Drive Monitoring" in Programming mode allows you to monitor the running status during maintenance and test running. Table 7.11 Drive Monitoring Items Page # in operation Item Symbol...
  • Page 542 Table 7.11 Drive Monitoring Items (Continued) Page # in operation Item Symbol Description guide Torque limit value A Driving torque limit value A (based on motor rated torque) Torque limit value B Driving torque limit value B (based on motor rated torque) Reference torque bias TRQB Reserved.
  • Page 543 7.4 Programming Mode Common operation items To access the target data, switch to the desired page using the keys. : This page continues to the next page. : This page is continued from the previous page and continues to the next page. : This page is continued from the previous page.

  • Page 544: Checking I/O Signal Status -- Menu #4 "I/O Checking

    7.4.5 Checking I/O signal status -- Menu #4 "I/O Checking" -- Menu #4 "I/O Checking" in Programming mode allows you to check the I/O states of digital and analog signals. It is used to check the running status during maintenance or test running. Table 7.12 I/O Check Items Page # in operation...
  • Page 545 7.4 Programming Mode Basic key operation (1) Turn the inverter ON. It automatically enters Running mode. In that mode, press the key to switch to Programming mode and display the menu screen. (2) Move the pointer to "4. I/O CHECK" with the keys.
  • Page 546 Common operation items To access the target data, switch to the desired page using the keys. : This page continues to the next page. : This page is continued from the previous page and continues to the next page. : This page is continued from the previous page. Figure 7.14 Screen Transition for "I/O Checking"...
  • Page 547 7.4 Programming Mode Digital output terminals [Y1] through [Y4] are assigned to bits 0 through 3. Each is given a value of "1" when it is short-circuited to [CMY], or a value of "0" when its circuit to [CMY] is open. The status of relay output terminal [Y5A/C] is assigned to bit 4, which assumes a value of "1"...

  • Page 548: Reading Maintenance Information -- Menu #5 "Maintenance Information

    7.4.6 Reading maintenance information -- Menu #5 "Maintenance Information" -- Menu #5 "Maintenance Information" in Programming mode shows information necessary for performing maintenance on the inverter. Table 7.14 Maintenance Information Items Page # in operation Item Symbol Description guide Shows the content of the cumulative power-ON time counter of the inverter.
  • Page 549 7.4 Programming Mode Table 7.14 Maintenance Information Items (Continued) Page # in operation Item Symbol Description guide Shows the content of the motor 1 startup counter (i.e., the number of run commands issued). Number of startups Note 1) When the count exceeds 65,530 hours, the counter will be reset to "0"...
  • Page 550 Table 7.14 Maintenance Information Items (Continued) Page # in operation Item Symbol Description guide Temperature inside the Shows the current temperature inside the inverter. TMPIM inverter (real-time value) Temperature of heat sink Shows the current temperature of the heat sink inside the TMPFM (real-time value) inverter.
  • Page 551 7.4 Programming Mode Table 7.14 Maintenance Information Items (Continued) Page # in operation Item Symbol Description guide Shows the factor of the latest light alarm as an alarm code. Light alarm (Latest) LALM1 For details, refer to Chapter 9, Section 9.1 "Protective Functions."...
  • Page 552 Basic key operation (1) Turn the inverter ON. It automatically enters Running mode. In that mode, press the key to switch to Programming mode and display the menu screen. (2) Move the pointer to "5. MAINTENANC" with the keys. (3) Press the key to establish the selected menu and proceed to a list of maintenance items (consisting of several pages).
  • Page 553 7.4 Programming Mode Common operation items To access the target data, switch to the desired page using the keys. : This page continues to the next page. : This page is continued from the previous page and continues to the next page. : This page is continued from the previous page.

  • Page 554: Reading Alarm Information -- Menu #6 "Alarm Information

    7.4.7 Reading alarm information -- Menu #6 "Alarm Information" -- Menu #6 "Alarm Information" in Programming mode shows the causes of the past four alarms that triggered protective functions, as an alarm code. It is also possible to display the related alarm information on the current inverter conditions detected when the alarm occurred.
  • Page 555 7.4 Programming Mode On the "detailed alarm info screens," you can view the information on the inverter running status at the time an alarm occurred. Table 7.15 lists the alarm information displayed on the LCD monitor. Table 7.15 Alarm Information Items Page # in operation Item...
  • Page 556 Table 7.15 Alarm Information Items (Continued) Page # in operation Item Symbol Description guide Simultaneously occurring alarm codes (1) Multiple alarm 1 ("----" is displayed if no alarm has occurred.) Simultaneously occurring alarm codes (2) Multiple alarm 2 ("----" is displayed if no alarm has occurred.) Error sub-code Secondary error code for alarms.
  • Page 557 7.4 Programming Mode Figure 7.17 shows an example of the LCD screen transition starting from Menu #6 "Alarm Information." 7-41...
  • Page 558 Common operation items To access the target data, switch to the desired page using the keys. : This page continues to the next page. : This page is continued from the previous page and continues to the next page. : This page is continued from the previous page. Figure 7.17 Screen Transition for "Alarm Information"...

  • Page 559: Viewing Causes Of Alarm -- Menu #7 "Alarm Cause

    7.4 Programming Mode 7.4.8 Viewing causes of alarm -- Menu #7 "Alarm Cause" -- Menu #7 "Alarm Cause" in Programming mode shows the causes of the past four alarms that triggered protective functions, as an alarm code. It also shows the cause of each alarm. Basic configuration of screens Figure 7.18 shows the LCD screen transition for Menu #7 "Alarm Cause."...
  • Page 560 Figure 7.19 shows an example of the LCD screen transition starting from Menu #7 "Alarm Cause." Common operation items To access the target data, switch to the desired page using the keys. : This page continues to the next page. : This page is continued from the previous page and continues to the next page.

  • Page 561: Data Copying -- Menu #8 "Data Copying

    7.4 Programming Mode 7.4.9 Data copying -- Menu #8 "Data Copying" -- Menu #8 "Data Copying" in Programming mode provides "Read," "Write," and "Verify," "Check," and "Protect" functions, enabling the following applications. The keypad can hold three sets of function code data in its internal memory to use for three different inverters.
  • Page 562 Basic configuration of screens Figure 7.20 shows the LCD screen transition for Menu #8 "Data Copying." A hierarchy exists among those screens that are shifted in the order of "menu screen," "list of copy functions," and "memory area selection screen." On the "memory area selection screen,"...
  • Page 563 7.4 Programming Mode Figure 7.21 Screen Transition for "Reading" Figure 7.22 Error Screens for "Reading" If an ERROR screen or an ERROR Ver. screen appears, press the key to reset the error condition. The screen returns to a list of copy functions. (2) Write 7-47...
  • Page 564 Figure 7.23 Screen Transition for "Writing" Figure 7.24 Error Screens for "Writing" If an ERROR screen or an ERROR Ver. screen appears, press the key to reset the error condition. The screen returns to a list of copy functions. 7-48...
  • Page 565 7.4 Programming Mode (3) Verify Figure 7.25 Screen Transition for "Verify" 7-49...
  • Page 566 Figure 7.26 Error Screen for "Verify" If an ERROR screen or an ERROR Ver. screen appears, press the key to reset the error condition. The screen returns to a list of copy functions. (4) Check Figure 7.27 Screen Transition for "Data Checking" 7-50...
  • Page 567 7.4 Programming Mode Figure 7.28 Error Screen for "Data Checking" If an ERROR screen appears, press the key to reset the error condition. The screen returns to a list of copy functions. (5) Protect Function code data can be protected from unexpected modifications. Enable the data protection on the "Reading"...

  • Page 568: Measuring Load Factor -- Menu #9 "Load Factor Measurement

    Figure 7.30 Warning Against Selecting Protected Data 7.4.10 Measuring load factor -- Menu #9 "Load Factor Measurement" -- Menu #9 "Load Factor Management" in Programming mode is used to measure the maximum output current, the average output current, and the average braking power. Two types of measurement modes are available as listed below.
  • Page 569 7.4 Programming Mode Figure 7.31 shows an example of the LCD screen transition starting from Menu #9 "Load Factor Measurement." Figure 7.31 Screen Transition for "Load Factor Measurement" (Limited duration measurement mode) 7-53...
  • Page 570 ( 2 ) Start-to-stop measurement mode Basic key operation (1) Turn the inverter ON. It automatically enters Running mode. In that mode, press the key to switch to Programming mode and display the menu screen. (2) Move the pointer to "9. LOAD FCTR" with the keys.
  • Page 571 7.4 Programming Mode Figure 7.32 Screen Transition for "Load Factor Measurement" (Start-to-stop measurement mode) Going back to Running mode When measurement of the load factor is in progress, pressing the key switches the inverter to Running mode, and pressing. the key, to the mode selection screen.

  • Page 572: Changing Function Codes Covered By Quick Setup -- Menu #10 "User Setting" --

    7.4.11 Changing function codes covered by Quick Setup -- Menu #10 "User Setting" -- Menu #10 "User Setting" in Programming mode is used to add or delete function code to/from the set of function codes registered for Quick Setup. Basic key operation (1) Turn the inverter ON.

  • Page 573: Helping Debugging For Communication -- Menu #11 "Communication Debugging

    7.4 Programming Mode 7.4.12 Helping debugging for communication -- Menu #11 "Communication Debugging" -- Menu #11 "Communication Debugging" in Programming mode is used to monitor the data of communication-related function codes (S, M, W, X, and Z codes) to help debug programs for communication with host equipment.

  • Page 574: Alarm Mode

    7.5 Alarm Mode If an abnormal condition arises so that the protective function is invoked and issues an alarm, then the inverter automatically switches to Alarm mode, displaying the alarm code on the LED monitor and the alarm information on the LCD monitor as shown below. Latest cause;...
  • Page 575 7.5 Alarm Mode It is also possible to view the alarm history. In addition to the latest (current) alarm, you can view past three alarms and multiple alarms (if any) using keys when the latest (current) one is displayed. Figure 7.37 Switching of Display of Overlapping Alarm History 7-59...
  • Page 576 Display of running status information at the time of alarm (Note 1 in Figure 7.38) By pressing the key while an alarm code is displayed, you can view the output frequency, output current, and other data concerning the running status. The data you can view is the same as with "6. ALM INF."...
  • Page 577 Chapter 8 RUNNING THROUGH RS-485 COMMUNICATION This chapter describes an overview of inverter operation through the RS-485 communications facility. Refer to the RS-485 Communication User's Manual for details. Contents 8.1 Overview on RS-485 Communication ......................8-1 8.1.1 RS-485 common specifications ......................... 8-2 8.1.2 Terminal specifications for RS-485 communications ................

  • Page 579: Overview On Rs-485 Communication

    8.1 Overview on RS-485 Communication Overview on RS-485 Communication The FRENIC-MEGA has two RS-485 communications ports at the locations shown below. (1) Communications port 1: RJ-45 connector for the keypad (2) Communications port 2: RS-485 terminals (Control circuit terminals SD, DX-, and DX+) RS-485 terminals (SD, DX-, and DX+) (which facilitate multi-drop connection.) COM port 1...

  • Page 580: Common Specifications

    8.1.1 RS-485 common specifications Items Specifications Protocol FGI-BUS Modbus RTU Loader commands (supported only on the standard version) Compliance Fuji general-purpose Modicon Modbus Dedicated protocol inverter protocol RTU-compliant (Not disclosed) (only in RTU mode) No. of supporting Host device: 1 stations Inverters: Up to 31...

  • Page 581: Terminal Specifications For Rs-485 Communications

    8.1 Overview on RS-485 Communication 8.1.2 Terminal specifications for RS-485 communications [ 1 ] RS-485 communications port 1 (for connecting the keypad) The port designed for a standard keypad uses an RJ-45 connector having the following pin assignment: Signal name Function Remarks 1 and 8...

  • Page 582: Connection Method

    8.1.3 Connection method • Up to 31 inverters can be connected to one host equipment. • The protocol is commonly used in the FRENIC series of general-purpose inverters, so programs for similar host equipment can run/stop the inverter. (The parameters specifications may differ depending on the equipment.) •...
  • Page 583 8.1 Overview on RS-485 Communication Multi-drop connection using the RS-485 communications port 2 (on the terminal block) Host equipment Host equipment USB or RS-232C RS-485 (4-wire) Terminating resistor (112 ) Shield USB RS-485 converter FRENIC-MEGA series Inverter 1 RS-232C RS-485 converter Station No.

  • Page 584: Communications Support Devices

    8.1.4 Communications support devices This section describes the devices required for connecting the inverter to a PC having no RS-485 interface or for connecting two or more inverters in multi-drop network. [ 1 ] Communications level converters Usually PCs are not equipped with an RS-485 communications port but with an RS-232C port. To connect inverters to a PC, therefore, you need an RS-232C–RS-485 converter or a USB–RS-485 converter*.
  • Page 585 8.1 Overview on RS-485 Communication [ 2 ] Requirements for the cable (COM port 1: for RJ-45 connector) Use a standard 10BASE-T/100BASE-TX LAN cable (US ANSI/TIA/EIA-568A category 5 compliant, straight type). The RJ-45 connector (COM port 1) has power source pins (pins 1, 2, 7 and 8) exclusively assigned to keypads.

  • Page 586: Noise Suppression

    8.1.5 Noise suppression Depending on the operating environment, instruments may malfunction due to the noise generated by the inverter. Possible measures to prevent such malfunction are: separating the wiring, use of shielded cable, isolating the power supply, and adding an inductance component. Shown below is an example of adding an inductance component.

  • Page 587: Overview Of Frenic Loader

    8.2 Overview of FRENIC Loader Overview of FRENIC Loader FRENIC Loader is a software tool that supports the operation of the inverter via an RS-485 communications link. It allows you to remotely run or stop the inverter, edit, set, or manage the function codes, monitor key parameters and values during operation, as well as monitor the running status (including alarm information) of the inverters on the RS-485 communications network.

  • Page 588: Connection

    (Note 1) FRENIC Loader cannot be used with inverters that do not support SX protocol (protocol for handling Loader commands). (Note 2) Use a PC with as high a performance as possible, since some slow PCs may not properly refresh the operation status monitor and Test-run windows.

  • Page 589: Function Overview

    8.2 Overview of FRENIC Loader 8.2.3 Function overview 8.2.3.1 Setting of function code You can set, edit, and check the setting of the inverter’s function code data. List and Edit In List and edit, you can list and edit function codes with function code No., name, set value, set range, and factory default.

  • Page 590: Multi-Monitor

    File information Clicking the File information tab displays the property and comments for identifying the function code editing file. (1) Property Shows file name, inverter model, inverter’s capacity, date of readout, etc. (2) Comments Displays the comments you have entered. You can write any comments necessary for identifying the file. 8.2.3.2 Multi-monitor This feature lists the status of all the inverters that are marked "connected"...

  • Page 591: Running Status Monitor

    8.2 Overview of FRENIC Loader 8.2.3.3 Running status monitor The running status monitor offers four monitor functions: I/O monitor, System monitor, Alarm monitor, and Meter display. You can choose an appropriate monitoring format according to the purpose and situation. I/O monitor Allows you to monitor the ON/OFF states of the digital input signals to the inverter and the transistor output signals.

  • Page 592: Test-Running

    8.2.3.4 Test-running The Test-running feature allows you to test-run the motor in the forward or reverse direction while monitoring the running status of the selected inverter. Select monitor item Frequency reference Select what is to be displayed (e.g., Enter or select the frequency command output frequency or current) here using to write it into the inverter.

  • Page 593: Real-Time Trace

    8.2 Overview of FRENIC Loader 8.2.3.5 Real-time trace The real-time trace monitors up to 4 analog readouts and up to 8 digital ON/OFF signals to display the running status of a selected inverter in real-time waveforms. • Sampling interval: Fixed at 200 ms •...

  • Page 594: Historical Trace

    8.2.3.6 Historical trace The historical trace monitors the running status of a selected inverter in greater detail with more contiguous waveforms than in the real-time trace. • Sampling interval: 1 to 200 ms • Size of data saved: 2 kilobytes •...

  • Page 595: Usb Port On The Optional Remote Keypad

    8.2 Overview of FRENIC Loader 8.2.3.7 USB port on the optional remote keypad The USB port on the optional remote keypad allows you to connect a computer supporting USB connection and use the FRENIC Loader. As described below, various information of the inverter saved in the keypad memory can be monitored and controlled on the computer.
  • Page 597 Chapter 9 TROUBLESHOOTING This chapter describes troubleshooting procedures to be followed when the inverter malfunctions or detects an alarm or a light alarm condition. In this chapter, first check whether any alarm code or the "light alarm" indication ( l-al ) is displayed or not, and then proceed to the troubleshooting items. Contents 9.1 Protective Functions ............................

  • Page 599: Protective Functions

    9.1 Protective Functions 9.1 Protective Functions The FRENIC-MEGA series of inverters has various protective functions as listed below to prevent the system from going down and reduce system downtime. The protective functions marked with an asterisk (*) in the table are disabled by default. Enable them according to your needs. The protective functions include, for example, the "alarm"...
  • Page 600 Related Protective function Description function code Upon receipt of the "Force to stop" terminal command STOP, this function Forced stop* interrupts the run and other commands currently applied in order to forcedly decelerate the inverter to a stop. This function protects the inverter from a surge voltage invaded between main Surge protection circuit power lines and the ground.
  • Page 601 9.1 Protective Functions Table 9.1 Abnormal States Detectable ("Alarm" and "Light Alarm" Objects) (Continued) "Alarm" "Light alarm" Ref. Code Name Remarks objects objects page Braking transistor broken 9-27 (Servo-lock) 9-27 Positioning control error (Synchronous control) 9-27 Enable circuit failure 9-27 l-al Light alarm 75 HP or above for...

  • Page 602: Before Proceeding With Troubleshooting

    "light alarm" indication ( l-al ) is displayed For problems that could be caused by running the inverter Go to Section 9.7. on single-phase power If any problems persist after the above recovery procedure, contact your Fuji Electric representative.

  • Page 603: If Neither An Alarm Code Nor "Light Alarm" Indication (L-Al) Appears On The Led Monitor

    9.3 If Neither an Alarm Code Nor "Light Alarm" Indication ( l-al ) Appears on the LED Monitor 9.3 If Neither an Alarm Code Nor "Light Alarm" Indication ( l-al ) Appears on the LED Monitor This section describes the troubleshooting procedure based on function codes dedicated to motor 1 which are marked with an asterisk (*).
  • Page 604 Possible Causes What to Check and Suggested Measures (6) No analog frequency Check whether the analog frequency command (reference frequency) is command input. correctly inputted, using Menu #4 "I/O Checking" on the keypad. Connect the external circuit wires to terminals [13], [12], [11], [C1], and [V2] correctly.
  • Page 605 9.3 If Neither an Alarm Code Nor "Light Alarm" Indication ( l-al ) Appears on the LED Monitor Possible Causes What to Check and Suggested Measures (14) Wrong connection or poor Check the wiring. contact of DC reactor Inverters of 100 HP or above require a DCR to be connected. Without a DCR, (DCR) these inverters cannot run.
  • Page 606 Possible Causes What to Check and Suggested Measures (9) The output frequency does Check whether data of torque limiter related function codes (F40, F41, E16 and not increase due to the E17) is correctly configured and the "Select torque limiter level" terminal torque limiter operation.
  • Page 607 9.3 If Neither an Alarm Code Nor "Light Alarm" Indication ( l-al ) Appears on the LED Monitor Possible Causes What to Check and Suggested Measures (5) The machinery is hunting Once disable all the automatic control systems such as auto torque boost, auto due to vibration caused by energy saving operation, overload prevention control, current limiter, torque low rigidity of the load.
  • Page 608 Possible Causes What to Check and Suggested Measures (4) Overload. Measure the output current. Reduce the load (For fans or pumps, decrease the frequency limiter value (F15).) (In winter, the load tends to increase.) (5) Torque generated by the Check that the motor starts running if the value of the torque boost (F09*) is motor was insufficient.
  • Page 609 9.3 If Neither an Alarm Code Nor "Light Alarm" Indication ( l-al ) Appears on the LED Monitor [ 9 ] The motor does not run as expected. Possible Causes What to Check and Suggested Measures (1) Incorrect setting of function Check that function codes are correctly configured and no unnecessary code data.

  • Page 610: Problems With Inverter Settings

    9.3.2 Problems with inverter settings [ 1 ] Nothing appears on the LED monitor. Possible Causes What to Check and Suggested Measures (1) No power (neither main Check the input voltage and interphase voltage unbalance. power nor auxiliary control Turn ON a molded case circuit breaker (MCCB), a residual-current- power) supplied to the operated protective device (RCD)/earth leakage circuit breaker (ELCB) inverter.

  • Page 611: If An Alarm Code Appears On The Led Monitor

    9.4 If an Alarm Code Appears on the LED Monitor 9.4 If an Alarm Code Appears on the LED Monitor [ 1 ] 0cn Instantaneous overcurrent Problem The inverter momentary output current exceeded the overcurrent level. Overcurrent occurred during acceleration. Overcurrent occurred during deceleration.
  • Page 612 [ 2 ] ef Ground fault Problem A ground fault current flew from the output terminal of the inverter. Possible Causes What to Check and Suggested Measures (1) Inverter output terminal(s) Disconnect the wiring from the output terminals ([U], [V], and [W]) and grounded (ground fault).
  • Page 613 9.4 If an Alarm Code Appears on the LED Monitor [ 4 ] lu Undervoltage Problem DC link bus voltage has dropped below the undervoltage detection level. Possible Causes What to Check and Suggested Measures (1) A momentary power failure Release the alarm.
  • Page 614 [ 6 ] 0pl Output phase loss Problem Output phase loss occurred. Possible Causes What to Check and Suggested Measures (1) Inverter output wires are Measure the output current. broken. Replace the output wires. (2) The motor winding is Measure the output current. broken.
  • Page 615 9.4 If an Alarm Code Appears on the LED Monitor [ 8 ] 0h2 External alarm Problem External alarm was inputted (THR). (when the "Enable external alarm trip" THR has been assigned to any of digital input terminals) Possible Causes What to Check and Suggested Measures (1) An alarm function of Check the operation of external equipment.
  • Page 616 Possible Causes What to Check and Suggested Measures Check whether decreasing the torque boost (F09*) does not stall the motor. (6) Excessive torque boost specified. (F09*) If no stall occurs, decrease the F09* data. Check if the base frequency (F04*) and the rated voltage at base frequency (7) The V/f pattern did not (F05*) match the values on the motor's nameplate.
  • Page 617 9.4 If an Alarm Code Appears on the LED Monitor [ 13 ] pbf Charger circuit fault Problem The magnetic contactor for short-circuiting the charging resistor failed to work. Possible Causes What to Check and Suggested Measures (1) The control power was not Check that, in normal connection of the main circuit (not a connection via the supplied to the magnetic DC link bus), the connector (CN R) on the power printed circuit board (power...
  • Page 618 [ 15 ] 0lu Inverter overload Problem Temperature inside inverter has risen abnormally. Possible Causes What to Check and Suggested Measures (1) Temperature around the Measure the temperature around the inverter. inverter exceeded the Lower the temperature (e.g., ventilate the panel where the inverter is inverter's specification mounted).
  • Page 619 Initialize the function code data by setting H03 to "1," then reset the alarm by pressing the key and check that the alarm goes on. The control PCB (on which the CPU is mounted) is defective. Contact your Fuji Electric representative. 9-21...
  • Page 620 [ 19 ] er2 Keypad communications error Problem A communications error occurred between the remote keypad or the multi-function keypad and the inverter. Possible Causes What to Check and Suggested Measures (1) Broken communications Check continuity of the cable, contacts and connections. cable or poor contact.
  • Page 621 9.4 If an Alarm Code Appears on the LED Monitor [ 23 ] er6 Operation protection Problem An incorrect operation was attempted. Possible Causes What to Check and Suggested Measures (1) The key was pressed Check that the key was pressed when a run command had been entered from when H96 = 1 or 3.
  • Page 622 [ 25 ] er8 RS-485 communications error (COM port 1) erp RS-485 communications error (COM port 2) Problem A communications error occurred during RS-485 communications. Possible Causes What to Check and Suggested Measures (1) Communications conditions Compare the settings of the y codes (y01 to y10, y11 to y20) with those of the of the inverter do not match host equipment.
  • Page 623 (1) The inverter capacity setting It is necessary to set the inverter capacity correctly. on the control printed circuit Contact your Fuji Electric representative. board is wrong. (2) Data stored in the power It is necessary to replace the power printed circuit board.
  • Page 624 Possible Causes What to Check and Suggested Measures (5) Wrong wiring between the Check the wiring between the PG and the inverter. pulse generator (PG) and the Correct the wiring. inverter. Check that the relationships between the PG feedback signal and the run command are as follows: For the FWD command: the B phase pulse is in the High level at rising edge of the A phase pulse...
  • Page 625 Check whether resistance of the braking resistor is correct or there is a broken. misconnection of the resistor. Consult your Fuji Electric representative for repair. [ 33 ] ero Positioning control error (Servo-lock) Problem An excessive positioning deviation has occurred when the servo-lock function was activated.

  • Page 626: If The "Light Alarm" Indication (L-Al) Appears On The Led Monitor

    9.5 If the "Light Alarm" Indication ( l-al ) Appears on the LED Monitor If the inverter detects a minor abnormal state "light alarm," it can continue the current operation without tripping while displaying the "light alarm" indication l-al on the LED monitor. In addition to the indication l-al , the inverter displays the "L-ALARM"...

  • Page 627: If An Abnormal Pattern Appears On The Led Monitor Except Alarm Codes And "Light Alarm" Indication (L-Al)

    9.6 If an Abnormal Pattern Appears on the LED Monitor except Alarm Codes and "Light Alarm" Indication ( l-al ) 9.6 If an Abnormal Pattern Appears on the LED Monitor except Alarm Codes and "Light Alarm" Indication ( l-al ) [ 1 ] –...
  • Page 628 [ 3 ] appears Problem Parentheses ( ) appeared on the LED monitor during speed monitoring on the keypad. Possible Causes What to Check and Suggested Measures (1) The display data overflows Check whether the output frequency multiplied by the display coefficient (E50) the LED monitor.

  • Page 629: If The Inverter Is Running On Single-Phase Power

    9.7 If the Inverter is Running on Single-Phase Power 9.7 If the Inverter is Running on Single-Phase Power [ 1 ] The AC fan(s) does not work. (230 V series with 60 HP or above or 460 V series with 125 HP or above) Possible Causes Suggested Measures The power supply is connected...

  • Page 631: Appendices

    Appendices Contents App. A Advantageous Use of Inverters (Notes on electrical noise) ..............A-1 A.1 Effect of inverters on other devices ......................A-1 A.2 Noise ................................ A-2 A.3 Noise prevention ............................A-4 App. B Japanese Guideline for Suppressing Harmonics by Customers Receiving High Voltage or Special High Voltage ..........................

  • Page 633: App. A Advantageous Use Of Inverters (Notes On Electrical Noise

    App. A Advantageous Use of Inverters (Notes on electrical noise) App. A Advantageous Use of Inverters (Notes on electrical noise) - Disclaimer: This document provides you with a summary of the Technical Document of the Japan Electrical Manufacturers' Association (JEMA) (April 1994). It is intended to apply to the domestic market only. It is only for reference for the foreign market.

  • Page 634: A.2 Noise

    Noise This section gives a summary of noises generated in inverters and their effects on devices subject to noise. [ 1 ] Inverter noise Figure A.1 shows an outline of the inverter configuration. The inverter converts AC to DC (rectification) in a converter unit, and converts DC to AC (inversion) with 3-phase variable voltage and variable frequency.
  • Page 635 App. A Advantageous Use of Inverters (Notes on electrical noise) [ 2 ] Types of noise Noise generated in an inverter is propagated through the main circuit wiring to the power supply and the motor so as to affect a wide range of applications from the power supply transformer to the motor. The various propagation routes are shown in Figure A.2.

  • Page 636: Noise Prevention

    Figure A.5 Electrostatic Induced Noise (3) Radiation noise Noise generated in an inverter may be radiated through the air from wires (that act as antennas) at the input and output sides of the inverter so as to affect peripheral devices. This noise is called "radiation noise"...
  • Page 637 App. A Advantageous Use of Inverters (Notes on electrical noise) [ 2 ] Implementation of noise prevention measures There are two types of noise prevention measures--one for noise propagation routes and the other for noise receiving sides (that are affected by noise). The basic measures for lessening the effect of noise at the receiving side include: Separating the main circuit wiring from the control circuit wiring, avoiding noise effect.
  • Page 638 What follows is noise prevention measures for the inverter drive configuration. (1) Wiring and grounding As shown in Figure A.7, separate the main circuit wiring from control circuit wiring as far as possible regardless of being located inside or outside the system control panel containing an inverter. Use shielded wires and twisted shielded wires that will block out extraneous noises, and minimize the wiring distance.
  • Page 639 App. A Advantageous Use of Inverters (Notes on electrical noise) (3) Anti-noise devices To reduce the noise propagated through the electrical circuits and the noise radiated from the main circuit wiring to the air, a line filter and power supply transformer should be used (refer to Figure A.10). Line filters are available in these types--the simplified type such as a capacitive filter to be connected in parallel to the power supply line and an inductive filter to be connected in series to the power supply line and the orthodox type such as an LC filter to meet radio noise regulations.
  • Page 640 [ 3 ] Noise prevention examples Table A.2 lists examples of the measures to prevent noise generated by a running inverter. Table A.2 Examples of Noise Prevention Measures Target Phenomena Noise prevention measures device Notes When operating an inverter, 1) Install an LC filter at the 1) The radiation noise radio noise enters into an AM radio...
  • Page 641 App. A Advantageous Use of Inverters (Notes on electrical noise) Table A.2 Continued Target Phenomena Noise prevention measures device Notes Telephone When driving a ventilation fan 1) Connect the ground 1) The effect of the (in a with an inverter, noise enters a terminals of the motors in inductive filter and common...
  • Page 642 Table A.2 Continued Target Phenomena Noise prevention measures device Notes Photo- A photoelectric relay 1) Insert a 0.1 F capacitor 1) If a low-current electric malfunctioned when the between the output circuit at the relay inverter was operated. common terminal of the malfunctioning amplifier of the side is observed,...
  • Page 643 App. A Advantageous Use of Inverters (Notes on electrical noise) Table A.2 Continued Target Phenomena Noise prevention measures device Notes Pressure A pressure sensor 1) Install an LC filter on the 1) The shielded parts sensor malfunctioned. input side of the inverter. of shield wires for sensor signals are 2) Connect the shield of the...

  • Page 644: Special High Voltage

    App. B Japanese Guideline for Suppressing Harmonics by Customers Receiving High Voltage or Special High Voltage - Disclaimer: This document provides you with a translated summary of the Guideline of the Ministry of Economy, Trade and Industry. It is intended to apply to the domestic market only. It is only for reference for the foreign market.

  • Page 645: Compliance To The Harmonic Suppression For Customers Receiving High Voltage Or Special High Voltage

    App. B Japanese Guideline for Suppressing Harmonics for Customers Receiving High Voltage or Special High Voltage (2) Regulation The level (calculated value) of the harmonic current that flows from the customer's receiving point out to the system is subjected to the regulation. The regulation value is proportional to the contract demand. The regulation values specified in the guideline are shown in Table B.1.
  • Page 646 Table B.2 "Input Rated Capacities" of General-purpose Inverters Determined by the Applicable Motor Ratings Applicable motor 0.75 18.5 rating (kW) 200 V 0.57 0.97 1.95 2.81 4.61 6.77 9.07 13.1 17.6 21.8 (kVA) 400 V 0.57 0.97 1.95 2.81 4.61 6.77 9.07 13.1...
  • Page 647 App. B Japanese Guideline for Suppressing Harmonics for Customers Receiving High Voltage or Special High Voltage (2) Calculation of harmonic current Usually, calculate the harmonic current according to the Sub-table 3 "Three-phase bridge rectifier with the smoothing capacitor" in Table 2 of the Guideline's Appendix. Table B.5 lists the contents of the Sub-table 3.
  • Page 648 Correction coefficient according to contract demand level Since the total availability factor decreases if the scale of a building increases, calculating reduced harmonics with the correction coefficient defined in Table B.7 is permitted. Table B.7 Correction Coefficient according to the Building Scale Contract demand (kW) Correction coefficient 1.00...
  • Page 649 App. B Japanese Guideline for Suppressing Harmonics for Customers Receiving High Voltage or Special High Voltage (2) Harmonic current every degrees [Example 1] 400 V, 3.7 kW 10 units, w/- AC reactor, and maximum availability: 0.55 Fundamental current Harmonic current onto 6.6 kV lines (mA) onto 6.6 kV lines (mA) 11th 13th...

  • Page 650: App. C Effect On Insulation Of General-Purpose Motors Driven With 400 V Class Inverters

    App. C Effect on Insulation of General-purpose Motors Driven with 400 V Class Inverters - Disclaimer: This document provides you with a summary of the Technical Document of the Japan Electrical Manufacturers' Association (JEMA) (March, 1995). It is intended to apply to the domestic market only. It is only for reference for the foreign market.

  • Page 651: Effect Of Surge Voltages

    App. C Effect on Insulation of General-purpose Motors Driven with 400 V Class Inverters Figure C.2 Measured Example of Wiring Length and Peak Value of Motor Terminal Voltage Effect of surge voltages The surge voltages originating in LC resonance of wiring may be applied to the motor terminals and depending on their magnitude sometimes cause damage to the motor insulation.

  • Page 652: Regarding Existing Equipment

    [ 1 ] Suppressing surge voltages There are two ways for suppressing the surge voltages, one is to reduce the voltage rise time and another is to reduce the voltage peak value. (1) Output reactor If wiring length is relatively short, the surge voltages can be suppressed by reducing the voltage rise time (dv/dt) with the installation of an AC reactor on the output side of the inverter.

  • Page 653: App. D Inverter Generating Loss

    App. D Inverter Generating Loss App. D Inverter Generating Loss The table below lists the inverter generating loss. Generating loss (W) Power LD mode MD mode HD mode supply Inverter type Low carrier High carrier Low carrier Low carrier High carrier voltage frequency frequency...

  • Page 654: App. E Conversion From Si Units

    App. E Conversion from SI Units All expressions given in Chapter 3, "SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES" are based on SI units (International System of Units). This section explains how to convert expressions to other units. [ 1 ] Conversion of units (1) Force (6) Inertia constant •...
  • Page 655 App. E Conversion from SI Units s [ 2 ] Calculation formula (1) Torque, power, and rotation speed (4) Acceleration torque Driving mode (r/min) • min) • • 1.026 (r/min) (kgf min) 9.55 • (kgf • (r/min) (kgf 0.974 • (r/min) Braking mode min)
  • Page 657 Glossary This glossary explains the technical terms that are frequently used in this manual.
  • Page 659 Glossary Acceleration time Auto search A period required for an inverter to increase its output Automatically searching for the rotational speed and from 0 Hz to the maximum frequency. It should be direction of the motor idling without power supplied specified, taking into account the inertia of the in order for the inverter to smoothly drive the idling machinery (load).
  • Page 660 Base frequency Constant torque load The minimum frequency at which an inverter’s output Machinery (load) that requires a constant torque voltage becomes constant. independent of the inverter’s output frequency (motor speed). The power consumption increases in Related function codes: F04, A02, b02 and r02 proportion to the motor speed.
  • Page 661 Glossary DC braking Dynamic torque vector control DC current braking that flows a DC current through A high performance control system in which the the motor stator windings to generate a magneto inverter calculates the flux and torque vectors based electric loss of the rotor.
  • Page 662 Filter Interphase (voltage) unbalance A filter that smoothens and cleans a signal, Interphase unbalance of three-phase AC input voltage eliminating unnecessary frequency band. Applying a (supply voltage) that is calculated by the following filter will produce a desirable effect in some cases: expression stipulated by the IEC Standard.
  • Page 663 Glossary Line speed Motor selection Traveling speed of a machine (e.g., conveyor) driven A general-purpose inverter can drive more than one motor by switching. A FRENIC-MEGA inverter can by the inverter-driven motor. The unit is meter per minute (m/min). The speed can be displayed on the drive up to four motors by switching with terminal keypad.
  • Page 664 Overload prevention control Rated output voltage An RMS voltage of a fundamental wave that is A function that detects inverter's heat sink overheat or overload and lowers the output frequency before the generated across the inverter’s output terminals when inverter trips, thus preventing the protective function the output frequency is equal to the base frequency.
  • Page 665 Glossary Simultaneous keying Speed response To simultaneously press two keys on the keypad, A performance index in speed control, which shows how many times the inverter can change the motor which is required for enabling some special keypad operations. shaft rotational speed with commands in one second. If this index is 100 Hz, for instance, it means that the inverter can respond to up to 100 speed commands per second.
  • Page 666 Switch to commercial power (SW50/SW60) Torque control To switch the power source for three-phase induction Controlling the motor output torque in vector control motors between the inverter output and commercial with speed sensor using the option card, in proportion power line. The switching sequence is integrated in to the analog input given at terminal [12].
  • Page 667 Glossary V/f characteristics Vector control with speed sensor Characteristics of an inverter output, frequency "f" A high-performance, high-response control mode, in which an inverter processes motor data such as the versus voltage "V." The graph below plots the output frequency along the abscissa, and the output voltage actual motor speed and motor shaft rotational angle along the ordinate.

  • Page 669: Index

    Index...
  • Page 671 Index Symbols Application functions 3, 5-21 1st S-curve acceleration range, 5-12 Application-defined control, 5-20 1st S-curve deceleration range, 5-12 Arrester, 4-1, 4-20 2nd S-curve acceleration range, 5-12 ASR switching time, 5-20 2nd S-curve deceleration range, 5-12 Atmosphere, 2-32, 2-33 2nd to 4th motor settings, 2-12 Atmospheric pressure, 2-32, 2-33 Auto energy saving operation, 2-12, 5-13, 5-93 Auto search for idling motor speed, 2-11...
  • Page 672 Braking unit and braking resistor (standard model) for boards, 5-12 LD-mode inverters, 4-26 Cumulative run time of cooling fan, 5-12 Braking unit and braking resistor (standard model) for Cumulative run time, 2-13 MD-mode inverters, 4-26 Current detection 2/Low current detection, 5-8 Braking unit, 4-1, 4-24, 4-29 Current detection 3, 5-8 Built-in braking resistor, 2-1, 2-2, 2-3, 2-4, 2-5, 2-6,...
  • Page 673 Index Digital output interface card, 4-1, 4-77 Factory defaults depending upon inverter capacity, 5-25 Display coefficient for input watt-hour data, 5-8 Fan units for braking units, 4-29 Drive command block, 6-4 Feedback input, 5-20 Drive control selection 1 to 4, 5-5, 5-14, 5-16, 5-18 Filter capacitor for radio noise reduction, 4-1 Drive control, 3-19 5-3, 5-103 Filter exclusive to RHC series, 4-1...
  • Page 674 HD (High duty) mode, 1-3 HD (High Duty: for heavy duty load applications), LCD monitor, 5-8 3-17 LD (Low duty) mode, 1-3 Heavy alarm, 7-8 LD (Low Duty: for light duty load applications), 3-17 Heavy duty load, 3-17 Leakage current, 2-38 High performance functions, 5-11 LED display filter, 5-8 Historical trace, 8-14...
  • Page 675 Index Momentary power failure protection, 2-15 OPC-G1-PG, 4-1, 4-65 Monitoring light alarms, 7-8 OPC-G1-PG2, 4-68 Motor 1 parameters, 5-11 OPC-G1-RY, 4-1, 4-72 Motor 1 to 4, 5-11, 5-14, 5-15, 5-16, 5-17, 5-18, 5-19 OPC-G1-SX, 4-1, 4-87 Motor 2 parameters, 5-14 OPC-G1-TL, 4-1, 4-84 Motor 3 parameters, 5-16 Open bus card, 4-1...
  • Page 676 PG wire break, 2-14, 2-57 Rated current of molded case circuit breaker (MCCB), 4-16 PID control, 2-11, 5-19, 5-193 Rated current sensitivity of residual-current-operated PID dancer control block, 6-14 protective device (RCD), 4-18 PID display coefficient, 5-8 Rated current, 2-1, 2-2, 2-3, 2-4, 2-5, 2-6, 2-7, 2-8 PID feedback wire break detection, 5-13 Rated voltage at base frequency 1 to 4, 5-4, 5-14, 5-16, PID feedback wire break, 2-14, 2-59...
  • Page 677 Index Surge suppression unit, 1-12, 4-1, 4-54 Saving of digital reference frequency, 5-8 Surge voltage, 1-12, 4-19, A-17 Screw specifications, 2-28 Surrounding temperature, 2-15, 2-32 S-curve acceleration/deceleration, 5-70 SW1, 2-26 Selecting inverter capacity, 2-38 Switch to commercial power, 5-115 Selection of normal/Inverse operation, 5-10 Switching between HD, MD and LD drive modes, 5-5 Service life of DC link bus capacitor, 5-13 SX-bus communications card, 4-1, 4-87...
  • Page 678 U codes, 5-21 UL standard, 1-13 Undervoltage protection, 2-13, 2-56 Universal AO, 2-12, 5-92 Universal DI, 2-12, 5-121 Universal DO, 2-12, 5-133 UP/DOWN control, 5-13 USB port, 2-25 USB, 8-15 V/f control block, 6-6 V/f control with speed sensor block, 6-8 V/f control, 3-20 V/f pattern, 5-67 Variable torque, 5-93...
  • Page 679 In no event will Fuji Electric Corp. of America be liable for any direct or indirect damages resulting from the application of the information in this manual.
  • Page 680 Fuji Electric Corp. of America 47520 Westinghouse Drive, Fremont, CA 94539 U.S.A Tel. 510-440-1060 Fax. 510-440-1063 www.americas.fujielectric.com...

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