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USER`S MANUAL

1. The brake switching circuit built in type of inverters with a capacity of 30 to 55 kW in 200 V class series and 30 to 110 kW in 400 V class series is available on request 1 3 2 Q VOAW OINSds OL NOILONGOUYLNI Accommodating various applications E 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 MEGA Ratio operation The ratio operation is convenient for synchronous control of two or more carrier machines in a multiline conveyor system It is possible to specify the ratio of the main speed to other follower motors as a frequency command so the conveying speed of carrier machines that handle variable loads or loading situations can be synchronously adjusted easily Ratio setting 82 Frequency command Ratio setting Ratio setting 90 95 Frequency command Frequency N command input T Input range 0 to 10 V 10 to 10 V 4 to 20 mA Main speed line speed Analog input Ratio setting Frequency command output Frequency command input x 100 0 E 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 freque
2. indication 4 is displayed or not and then proceed to the troubleshooting items Appendices Glossary Index Icons The following icons are used throughout this manual C Note 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 Gip This icon indicates information that can prove handy when performing certain settings or operations Li This icon indicates a reference to more detailed information FO Eten Fuji Electric 13916183699 iv 021 60510862 CONTENTS Chapter 1 INTRODUCTION TO FRENIC MEGA EE WC AU CS an A inae vaton ae tatsacuebaae A E A 1 1 I2 OLS y St a era att aa a A acl a 1 12 Dee RTS Oi yO Mia VOC sa ac cocoa eal oe ea 1 12 De Mor Oye COMO Sse a a a a a 1 13 LS External Viewand Terminal Blocks meiiies a e a a 1 14 LA Recommended Conor Om asar ain kea A E 1 16 Chapter 2 SPECIFICATIONS Dede ptandard INFO GCS sciatic n E E E 2 1 2 1 1 Three phase 200 V class series HD and LD mode inverters nnnnnnnnnnnnneeeenesesserserrsrrererrresren 2 1 2 1 2 Three phase 400 V class series HD and LD mode inverters nnnnnnennnnnneseeessesrrrseressrererrreseen 2 2 22 COMMOBA PEC CAUIOMS ea nn a E EE a A NEE ER 2 3 2 demmimalspecineaAlONS eeo a T a a a A N 2 10 Zak Termina UCU ONS enra aaa a E etree aaa vaedasah duro Ane 2
3. 52 74 10 15 20 25 30 40 48 58 71 oe PPP tt e ta tte pets te C e e Poe is 0 ame 2 we Beee uaa mes uo Jaja OCC Dyed EEE S e w o Jej oo o O DC reactor DCR Option oo O UL508C C22 2No 14 EN61800 5 1 2003 applied Weight Mass te 18 2028 30 32 6s 707 es es Ble lela 2 3 D 3 N SNOILVOlsalIOAdS Output ratings a v E e ae oa _ a E Fuji 4 pole standard motor 2 Rated capacity is calculated assuming the rated output voltage as 220 V for 200 V class series and 440 V for 400 V class series 3 Output voltage cannot exceed the power supply voltage 4 To use the inverter with the carrier frequency of 3 kHz or more at the surrounding temperature of 40 C or higher manage the load so that the current comes to be within the rated ones enclosed in parentheses in continuous running 5 Max voltage V Min voltage V Voltage unbalance x 67 IEC61800 3 Three phase average voltage V If this value is 2 to 3 use an optional AC reactor ACR 6 Required when a DC reactor DCR is used 7 Average braking torque for the motor running alone It varies with the efficiency of the motor 8 For inverters with a capacity of 55 kW a DCR is provided as standard or option for LD or HD mode respectively Note A box LJ in the above table replaces A E J or T depending on the shipping destination 2 1 2 1 2 Three phase 400
4. Fo e Front runners FO ate Fuji Electric 13916183699 021 60510562 USER S MANUAL Fo Sten Fuji Electric 13916183699 021 60510862 MEH278a High Performance Multifunction Inverter FRENIC MEGA User s Manual Fo teil Fuji Electric 13916183699 021 60510862 Copyright 2007 2008 Fuji Electric FA Components amp Systems Co Ltd All rights reserved No part of this publication may be reproduced or copied without prior written permission from Fuji Electric FA Components amp Systems Co Ltd All products and company names mentioned in this manual are trademarks or registered trademarks of their respective holders The information contained herein is subject to change without prior notice for improvement 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 The table below lists the other materials related to the use of the FRENIC MEGA Read them in conjunction with this manual as necessary Name Material No Description Product scope features specifications external Catalog MEH642 drawings and options of the product Acceptance inspection mounting amp wiring of the INR
5. is turned to the PTC NTC position For details on SWS refer to Setting up the slide switches on page 2 20 In this case you must change data of the function code H26 13 lt Control circuit gt Q DC 10 V Resistor 27KQ i v2 SW5 Operation level V2 H27 H27 Compartor External PTC NTC PTC NTC alarm thermistor H26 11 OV Figure 2 1 Internal Circuit Diagram SW5 Selecting PTC NTC 11 Analog common Common for analog input output signals 13 12 C1 V2 and FMA Isolated from terminals CM s and CMY 2 11 Related Functions function codes Since low level analog signals are handled these signals are especially susceptible to the external noise effects Route the wiring as short as possible within 20 m and use shielded wires In principle ground the shielded sheath of wires if effects of external inductive noises are considerable connection to terminal 11 may be effective As shown in Figure 2 2 be sure to ground the single end of the shield to enhance the shield effect Use a twin contact relay for low level signals if the relay is used in the control circuit Do not connect the relay s contact to terminal 11 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 t
6. vol Target stop point Position detection sensor LS 1 5 The interface is available in 10 steps using 2 inputs 1 output logical operation and the timer function Introducing servo lock function PG option card Available soon This function is effective in adjusting the stop timing or the braking torque when the equipment such as a conveyance machine is stopped by positioning of the motor This function is helpful when torque is applied externally or holding torque is required during the stop time The tact time per cycle will be reduced by shortened deceleration time Wide model variation meeting the customer needs E Wide model variation 1 Basic type Suitable for the equipment that uses a peripheral device to suppress noise or harmonics 2 EMC filter built in type available soon This type has a built in EMC filter and is compliant with European EMC Directives Objective standard Category C3 2nd Env EN61800 3 2004 compliant Use of EMC filter will increase the leakage current 3 Inverter type designed to the guideline specified by the Ministry of Land Infrastructure and Transport available soon The inverter employs a DC reactor and complies with Standard Specifications for Public Building Construction supervised by the Ministry of Land Infrastructure and Transport This inverter suppresses harmonics and noise The inverter incorporates the DC reactor and the zero phase reactor is supplied
7. Customers Receiving High Voltage or Speca H CENONE on E Aaascntbasa eeancaaasee A 12 B I Application to general purpose InVerters ciei ie oii en aa A 12 B 2 Compliance to the harmonic suppression for customers receiving high voltage or special Meh VONAGE 53 5 5 5s cssn acd a a a a e a a a a A 13 App C Effect on Insulation of General purpose Motors Driven with 400 V Class Inverters 00008 A 17 C 1 Generating mechanism of surge voltages 00000nnonnnonnssnssseessssssssnsssssssssssssssssnsssssssnssssssssssssssseenenno A 17 C2 EHector surve YONA ES RT E A N A 18 C 3 Countermeasures against surge voltages ac css ses cc vessacsiaveesseiabeta ena dessa tsabeavedshdeesadeiabsiedseies a tacbessedstavooeees A 18 CA Recarding xistine CQUIPMICI vein cos aneura gn S E A A 19 App D Inverter Generating LOSS contests este eee A E AR et ede E AOA A 20 App F CONVE ron Tron SI WINS ji ios cinta a A R TAE A eee ee A 21 App F Allowable Current of Insulated WiteS ics sit stn ocseeaede rtd dahon eaten E L A 23 Apo G Replacement Informat omiaa re E a a a ants A 25 G 1 External dimensions comparison tables 00000oooonneeeeeeeeeeeeneessesssssnsssssssssssssssssssssssssnsssssssssssssssennenno A 25 G 2 Terminal arrangements and symbols ccccccccccccccecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees A 28 Gr TOn HONCode S earna A eau A E nist audio EEI CENA A 35 Glossary Index vill Chapter 1 IN
8. Equipment Inverters Software libraries Then download the FRENIC MEGA Loader setup version Message Manager for FRENIC MEGA PC Loader and Loader Software for FRENIC MEGA Instruction Manual Before downloading you are requested to register as a member free of charge Cote e Route the wiring of the control circuit terminals as far from the wiring of the main circuit as possible Otherwise electric noise may cause malfunctions Fix the control circuit wires with a cable tie inside the inverter to keep them away from the live parts of the main circuit such as the terminal block of the main circuit 2 19
9. S147 1183 E inverter operation using the keypad running the motor INR S147 1223 E for a test troubleshooting and maintenance and inspection Instruction Manual Overview of functions implemented by using FRENIC MEGA RS 485 communications facility its communications specifications Modbus RTU Fuji RS 485 general purpose inverter protocol and functions and Communication MEH448 related data formats User s Manual Note The RS 485 Communication User s Manual is as of September 2005 Although it does not specifically refer to the FRENIC MEGA all descriptions are intended for all types of inverters The materials are subject to change without notice Be sure to obtain the latest editions for use Guideline for Suppressing Harmonics in Home Electric and General purpose Appliances Our three phase 200 V class series inverters of 3 7 kW or less FRENIC MEGA series were the products of which were restricted by the Guideline for Suppressing Harmonics in Home Electric and General purpose Appliances established in September 1994 and revised in October 1999 issued by the Ministry of Economy Trade and Industry The above restriction however was lifted when the Guideline was revised in January 2004 Since then the inverter makers have individually imposed voluntary restrictions on the harmonics of their products We as before recommend that you connect a reactor for suppressing harmonics to your inverter As a reactor sele
10. Speed control accuracy 0 5 E lt Current response 500 Hz Torque accuracy 10 Fo Eten Fuji Electric 13916183699 021 60510862 1 1 E Fuji s original dynamic torque vector control has further upgraded Besides the dynamic torque vector control the inverter 1s 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 This realizes a high starting torque of 200 even at a low speed rotation of 0 3 Hz 250 414 200 100 4 Motor speed r min anbsoy 100 200 250 4 Example torque characteristics 5 5kW E Improved reaction to the fluctuation of impact load When a remarkable load fluctuation occurs the inverter provides the torque response in the class top level It controls the flux to minimize the fluctuation in the motor speed while suppressing the vibration This function is best suited for equipment that requires stable speed such as a cutting machine Example FRENIC MEGA Our previous model MEGA controls the speed and torque better than the previous models in the settled state Load torque 1 1 Features E 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 t
11. Two common terminals for digital input and FMP output signals These terminals are electrically isolated from other common terminals 11 s and CMY These are the shared terminals with the digital input terminal CM s 2 16 2 3 Terminal Specifications Symbol Name Functions Classifi cation 2 gt 3 N Y1 Transistor 1 Various signals such as inverter running speed freq arrival output 1 and overload early warning can be assigned to any terminals l Y1 to Y4 by setting function code E20 to E24 Refer to Y2 Chapter 5 FUNCTION CODES for details output 2 Switches the logic value 1 0 for ON OFF of the terminals Y3 Transistor between Y1 to Y4 and CMY If the logic value for ON output 3 between Y1 to Y4 and CMY is 1 in the normal logic system for example OFF is 1 in the negative logic system Transistor and vice versa output 4 SNOILVOlsalIOAdS Transistor output circuit specifications lt Control circuit gt uae Cunt Figure 2 7 Transistor Output Circuit Max oF gt O Q A N z Sn Maximum motor mA current at ON Leakage current mA Figure 2 8 shows examples of connection between the control circuit and a PLC Chote e When a transistor output drives a control relay connect a surge absorbing diode across relay s coil terminals When any equipment or device connected to the transistor output needs to be supplied
12. V class series 400 VDC 400 V class series 800 VDC in the DC link circuit is detected and the inverter is stopped If an excessive voltage is applied by mistake the protection cannot be guaranteed The voltage drop 200 V class series 200 VDC 400 V class series 400 VDC in the DC link circuit is detected to stop the inverter However the alarm will not be issued when the re starting after instantaneous stop is selected e The input phase loss is detected to shut off the inverter output This function protects the inverter e When the load is small or a DC reactor is connected a phase loss may not be detected Output phase loss SE ee a sees Detects breaks in inverter output wining during running to shut off the inverter output Overheat protection 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 200 V 45 kW 400 V 75 kW or above Stop the inverter output detecting inner temperature of the inverter unit for a cooling fan fault or overload Protect the braking resistor from over heat by setting the braking resistor electronic thermal function Overload protection Stops the inverter output upon detection of the abnormal heat sink temperature and switching element temperature calculated with the output current External alarm input With the digital input signal THR opened the inverter is
13. X1 to X9 FWD or REV ON or OFF In circuit a the slide switch SW1 has been turned to SINK whereas in circuit b it has been turned to SOURCE Note To configure this kind of circuit use a highly reliable relay Recommended product Fuji control relay Model HH54PW lt Control circuit gt lt Control circuit gt X1 to X9 FWD REV Photocoupler Photocoupler a With the switch turned to SINK b With the switch turned to SOURCE Figure 2 5 Circuit Configuration Using a Relay Contact E Using a programmable logic controller PLC to turn X1 to X9 FWD or REV ON or OFF Figure 2 6 shows two examples of a circuit that uses a programmable logic controller PLC to turn control signal input X1 to X9 FWD or REV ON or OFF In circuit a the slide switch SW1 has been turned to SINK whereas in circuit b it has been turned to SOURCE In circuit a below short circuiting or opening the transistor s open collector circuit in the PLC using an external power supply turns ON or OFF control signal X1 to X9 FWD or REV When using this type of circuit observe the following Connect the node of the external power supply which should be isolated from the PLC s power to terminal PLC of the inverter Do not connect terminal CM of the inverter to the common terminal of the PLC 2 14 2 3 Terminal Specifications Functions Classifi 2 gt N lt Control circ
14. between terminals V2 and 11 and set the switch on control print board and the function 2 code WLI D LHII NTC thermistor The NTC thermistor detects a motor temperature Connect a NTC thermistor between O x 5 terminals V2 and 11 and set the switch on control print board and the function code NTC thermistor cas i Stop the inverter output detecting the built in motor NTC breaking Wo breaking Overload early Warning signal is output at the predetermined level before stopping the inverter with warning electronic thermal function Memory error Data is checked upon power on and data writing to detect any fault in the memory and to _ stop the inverter if any LI l Keypad The keypad is used to detect a communication fault between the keypad and inverter main _ 5 i k LIL communications error body during operation and to stop the inverter CPU error Stop the invert detecting a CPU error or LSI error caused by noise Era Option When each option is used a fault of communication with the inverter main body is a communications error detected to stop the inverter LI 1 Option error When each option is used the option detects a fault to stop the inverter Era Operation protection STOP key priority Pressing the gro key on the keypad or entering the digital input signal will forcibly decelerate and stop the motor even if the operation command through signal input or communication is selected 4 will b
15. for four kinds of specific functions can be switched even during operation It is possible to set the base frequency rated current torque boost and electronic thermal slip compensation as the data for 1st to 4th motors The status of external digital signal connected with the universal digital input terminal is transferred to the host controller Digital command signal from the host controller is output to the universal digital output terminal terminal Overload stop function When the torque or the current exceeds the specified level the inverter decelerates the motor to a stop or allows the motor to coast to a stop When the motor is interrupted by a mechanical stop the inverter controls the current to secure the holding torque 1 to 5 Speed control e Notch filter for vibration control vibration suppressing observer 7 e Estimates the GD2 value applied to the motor shaft from the load and automatically controls the ASR system constant 6 and 7 Preliminary excitation Excitation is carried out to create the motor flux before starting the motor 6 and 7 Zero speed control The motor speed is held to zero by forcibly zeroing the speed command 7 Stops the motor and holds the motor in the stopped position 7 8 Torque control 6 7 Analog torque command input 8 e Speed limit function is provided to prevent the motor from becoming out of control Rotational direction i Select either of reverse or forward rot
16. in a transistor output signal Surrounding temperature 40 C Load rate inverter rated current 100 LD mode 80 Displays the inverter cumulative run time input watt hour cumulative motor run time and the number of startups of each motor Outputs the warning when the maintenance time or the number of start times has exceeded the preset Displays the cause of trip by codes Light alarm Shows the light alarm display 4 Running or trip mode e Trip history Saves and displays the cause of the last four trips with a code e Saves and displays the detailed operation status data of the last four trips Overcurrent protection Overcurrent protection The inverter is The inverter is stopped for protection against overcurrent for The inverter is stopped for protection against overcurrent against overcurrent Short circuit The inverter is stopped for protection against overcurrent caused by a short circuit in the protection output circuit Ground fault protection Overvoltage protection Undervoltage protection Input phase loss protection The inverter is stopped for protection against overcurrent caused by a ground fault in the output circuit 200 V 22 kW 400V 22 kW or below Detecting zero phase current of output current the inverter is stopped for protection against overcurrent caused by a ground fault in the output circuit 200 V 30 kW 400 V 30 kW or above An excessive voltage 200
17. part Designed life Main circuit capacitor 10 years Electrolytic capacitor on PCB 10 years Cooling fan 10 years VOAW OINSdsA OL NOILONGOUYLNI The part life conditions that the inverter is used at a Surrounding temperature of 40 C and under the load rate of 100 HD mode or 80 LD mode The designed lives are the calculated values and not the guaranteed ones E Full support of life warnings The inverter has the following functions for facilitating the maintenance of the machinery Item Purpose Displays the total run time of the inverter by counting the ene ON time of the main power by hours Displays the total run time of the motor Cumune motorrin tim Used to judge the service life of machinery load Unit 10 hours Even when the motor is driven by commercial power it is also possible to count the cumulative motor run time using digital input signals Displays the number of motor startups This count can be used as a guide for replacement timing of machinery parts such as timing belts that undergo load in ordinary operation Cumulative startup count Equipment maintenance warning Makes it possible manage the total run time of the motor and the number of startups Such data is usable for preparing the maintenance schedule Cumulative motor run time Unit 10 hours Cumulative startup count Displays the following Current capacitance of DC link bus capacitor Total run time of the cooling
18. s output frequency The current running through the motor on the other hand has a fairly smooth alternating current AC waveform shown on the right hand side Current waveform of Figure 1 2 thanks to the inductance of the motor coil The control block section controls the PWM so as to bring this current waveform as close to a sinusoidal waveform as possible Cm AO PWM voltage waveform Current waveform Figure 1 2 Output Voltage and Current Waveform of the Inverter For the reference frequency given in the control block the accelerator decelerator processor calculates the acceleration deceleration rate required by run stop control of the motor and transfers the calculated results to the 3 phase voltage processor directly or via the V f pattern processor whose output drives the PWM block to switch the power gates 1 2 Control System 1 2 2 Motor drive controls 2 J Q O The FRENIC MEGA supports the following motor drive controls V f control a NEE Frequency control with slip compensation inactive Dynamic torque vector control V f control Disable Frequency control with slip compensation V f control act ve with slip compensation active Speed control with Vector control with speed sensor Vector control Enable automatic speed regulator ASR VOAW OINSds OL NOILONGOUYLNI Additionally the FRENIC MEGA reserves motor drive controls shown below for future support options V f control with
19. speed sensor Dynamic torque vector control with speed sensor Vector control without speed sensor The controls marked with an asterisk require an optional PG Pulse Generator interface card For the features of the controls refer to Chapter 3 Section 3 4 1 Features of motor drive control Fo ztn Fuji Electric 13916183699 1 13 021 60510862 1 3 External View and Terminal Blocks 1 External views Keypad ah igs Warning plate Front cover Main nameplate Front cover Front cover fixing screw Sub nameplate Wiring guide ___ 2 gt Be AN Control circuit terminal block Main circuit terminal block Figure 1 3 FRN11G1S 20 Cooling fans base E Charging lamp Warning plate Front cover Main nameplate Top mounting Internal air circulation fan Keypad enclosure openable Control circuit terminal block tj s d H NT E 7 A a gt Y a A Y A Y AN u T y Main circuit ion caver terminal block Figure 1 4 FRN30G1S 40 Note A box LJ in the above model names replaces A E J or T depending on the shipping destination 1 3 External View and Terminal Blocks 2 Terminal block location 2 2 Q O E LN TEF Fe Mahi SAKE Control Circuit Z Terminal Symbol A PI Plate 4 O Sub Wiring e nameplate Control Circuit z guide m AS Terminal Block
20. stopped with an alarm Fuse blown Stop the inverter output detecting the fuse breaking of the main circuit in the inverter 200 V 75 kW 400 V 90 kW or above Charge circuit fault Stop the inverter output detecting the charge circuit abnormality in the inverter 200 V 37 kW 400 V 75 kW or above 6 Available under vector control without speed sensor 7 Available under vector control with speed sensor PG option required 2 Remarks rw LIL I W 7 LILL LIL I Lil russ LILI I TU 11 LILI TU 11 LILII st LLI L NMI TU LMI L TUI I LIII TUII LI II L LI LILII I UH I1 LIL LI TUII LN IL 2 gt 3 N SNOILVO IldJIOJdS fen Remark Stop the inverter detecting the brake transistor abnormality Braking transistor Watt brok EUW roken DB transistor built in type only Overspeed protection Stop the inverter when the detected speed exceeds 120 of maximum output frequency gt LII 4 to 7 Kg PG wire break 4 5 7 Stop the inverter detecting the PG braking Fii Electronic thermal The inverter is stopped with an electronic thermal function set to protect the motor H Ria Protects the general purpose motor inverter over all frequency range The running level p hy j LIL I and thermal time constant 0 5 to 75 0 min can be set a PTC thermistor A PTC thermistor input stops the inverter to protect the motor Connect a PTC thermistor
21. together with the inverter to meet the inverter installation standards stipulated in the Standard Specifications for Public Building Construction Electric Equipment 2004 version published under the supervision by Government Buildings Department in Minister Secretariat of Land Infrastructure and Transport FO sten Fuji Electric 13916183699 021 60510862 1 6 1 1 Features Supports for simple maintenance 2 Q O E The built in USB port allows use of an inverter support loader FRENIC loader for easy information control Improved working efficiency in the manufacturing site A variety of data about the inverter body can be saved in the keypad memory allowing you to check the information in any place Example of use in the office Features 1 The keypad can be directly connected to the computer through a commercial USB cable mini B without using a converter The computer can be connected on line with the inverter 2 With the FRENIC loader the inverter can support the following functions 1 to 5 VOAW OINSds OL NOILONGOUYLNI 1 Editing comparing and copying the function code data 2 Operation monitor real time trace 3 Trouble history indicating the latest four trouble records 4 Maintenance information 5 Historical trace available soon Data can be directly transferred from the keypad via the USB port to the computer FRENIC loader at the manufacturing site Peri
22. 10 2 3 2 Terminal arrangement diagram and Screw SpecificatiOns cccccccccccccccccsecceeeceeeeeceeeeeeeeeeeeseesseeeeeess 2 22 DADAM Man Ci CUT LETT ANS cise Nich cao ars ne leased basco otal ca aN dats ade a da ears atsuet 2 22 2222 ACOMOMCICUIL TERMI S A iiqatieitia sie toasnsdeusvenn a a E R 2 24 2 4 Operating Environment and Storage Environment ccccceeesssseeseseseesssssssssssssssssssssssssssssssseeeeeaaas 2 25 ZAM Operiine CHV IPO MCI ezgaxs oso coe caso eE eae TE E E OE 2 25 2A SOTE CV ONNEN Ao pa cat tn cadaunad pect a a dentn teeta e dentate Meandacinan 2 26 2A Temporary SCOR AG Correos R ean EE EA Salus vec E sates ald E E ES 2 26 Aa Lone UST SO C pea a a a Syaesaaes 2 26 29 SPrecauti ns Tor USNE Verners eorna a tee E a hav nhs N T E E TE 2 27 23 Precautions in introducing INVITEES nennen AE a E A Aa 2 27 232 Procautions m nning Yere S euceart 2 32 2 5 3 Precautions in using special MOtOTS nsseseneneerrnnrerrrrrrrrrerrrrrreeessssresrsrerssrsssrerreserereseersereersrrreeees 2 32 210 Exte eC Dimension saaa a a a a a a me ere nee 2 34 O Sondar node a a a A 2 34 TO EPa e ee a E A A A EO 2 38 2A Comecon Dae 2c 1 ea a RE N E A A A E A A A 2 39 2e Runnne a Standard Motoi mensenn a a E a a 2 39 2 7 2 Running a Fuji motor exclusively designed for vector control cececccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 2 41 2 MPLOVCCIIVE FUNCIONS wara r a TS 2 43 Chapter 3 SELECTING OPTIMAL MOTOR
23. 15 Link operation Frequency can be specified through RS 485 Standard setting Frequency setting Two types of frequency settings can be switched with an external signal digital input Remote local switching link switching Auxiliary frequency setting Inputs at terminal 12 C1 or V2 can be added to the main setting as auxiliary frequency settings Operation at a specified ratio The ratio can be set by analog input signal Inverse operation Switchable from 0 to 10 VDC 0 to 100 to 10 to 0 VDC 0 to 100 by external command Switchable from 4 to 20 mA DC 0 to 100 to 20 to 4 mA DC 0 to 100 by external command Pulse train input standard Pulse input Terminal X7 Rotational direction general terminal Complementary output Max 100 kHz Open collector output Max 30 kHz Pulse train input option PG interface option CW CCW pulse pulse rotational direction Complementary output Max 100 kHz Open collector output Max 25 kHz Setting range Between 0 00 and 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 deceleration pattern Linear acceleration deceleration S shape acc
24. 3 Droop control Decreases the speed according to the load torque Torque limit e Switchable between Ist and 2nd torque limit values e Torque limit torque current limit and power limit are set for each quadrant 6 7 e Analog torque limit input Software current Automatically reduces the frequency so that the output current becomes lower than the limiter preset operation level 1 to 5 PID Control e 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 feedback value from terminals 12 C1 and V2 Alarm output absolute value alarm deviation alarm PID output limiter Integration reset hold e Anti reset wind up function Auto search for idling The inverter automatically searches for the idling motor speed to be harmonized and starts motor speed to drive it without stopping it Motor electric constant needs tuning Offline tuning 1 to 3 and 6 Available under V f control 2 Available under dynamic torque vector control 3 Available when the slip compensation is made active under V f control 4 Available under V f control with speed sensor PG option required 5 Available under dynamic torque vector control with speed sensor PG option required 6 Available under vector control withou
25. 7 4 1 Setting up basic function codes quickly Menu 0 Quick Setup cccccccccccccccccceeeeeeeeeeeeeeees 7 19 7 4 2 Setting up function codes Menu 1 Data Setting 2 cccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 22 7 4 3 Checking changed function codes Menu 2 Data Checking cccccccccccceceeeeeeeeeeeeeeeeeeeeeeees 7 25 7 4 4 Monitoring the running status Menu 3 Drive Monitoring cece ec ccccccccccccceeeecceeeeeeeeeeeeeees 7 26 7 4 5 Checking I O signal status Menu 4 I O Checking cccccccccccceeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 30 7 4 6 Reading maintenance information Menu 5 Maintenance Information cccccceeeeeees 7 35 7 4 7 Reading alarm information Menu 6 Alarm Information ccccccccccccccccceceeeeeeeeeeeeeeeeeeeeees 7 40 7 4 8 Copying data Menu 7 Data Copying cccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 43 De A VOC Ci sarcssaneketrnt nance cea a oacamnontnmnie ecu aaseane mane a weauet anionic aed 7 46 7 5 1 Releasing the alarm and switching to Running mode cece ccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 46 Ta Displayine erdlarin MSto enaner nudes aidndeae a nee aaes 7 46 7 5 3 Displaying the status of inverter at the time Of alarm cc cccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 7 46 7 5 4 Switching to Programming mode ccccccccccccceccscccscccccces
26. AND INVERTER CAPACITIES Salt Selectinme Motors and TVEren aaa til ng Se ed T E eta ricer eee eis 3 1 5 1 Motor output torque characlenstiCs 23 0sn aed Bhai or ee es 3 1 Pdl ACC CULO Ol OC IE og tee a a ana e a 3 4 Jd Eauanons orse lecionSssei a A N A A 3 7 3 1 3 1 Load torque during constant speed running ccc eeeceeeeeeeeeeeeeeeeeeesesesssseeeaessaeaeeeasseaeeaaaaaaeeees 3 7 3 1 3 2 Acceleration and deceleration time calculatiorn csent aai iaaea aiaiai 3 9 3 1 3 3 Heat energy calculation of braking resistor nnnnnnnnneeneeeeeseererrrrrrrrrrrrrerrnrrreerssssssssssssesess 3 14 3 1 3 4 Calculating the RMS rating of the motor 0 0 eeeescceeeeeeeeceececceeececeeceeceeeeeeceeeeeeeeeeeeeeeeeeeees 3 15 Ja DPCleCHNSG a Braking RESISUOL arien a E a a TAE nA 3 16 Lal SelecHomprocedUT E aie a E T E sealed dade senee enna 3 16 o OP E OE e O E E E E E E 3 16 oo selectne an Inverter Dive Mode ssc tsecmsscchsasiwntansenone sens EE EE T EE AE apenas 3 17 3 3 1 Precaution to inverter drive mode selection between HD and LD modes cecceeeeeeeeeeeees 3 17 3 3 2 Guideline for selecting inverter drive mode and Capacity cc cccccccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 3 17 oo selectine a Motor Dive Cont oleen usri a E E E ae eee 3 18 2A Features OF motor driye contol siooni a corsa Re 3 18 Chapter 4 SELECTING PERIPHERAL EQUIPMENT kk lt Comiiourine ne FRENICEME io 3c 80s coceat sits bia Stina a a a a
27. AQ selectine Wires and Crimp Terminal Ss cries odsataaccssesceascttaceasbaasseodowsa eons aes saaaottaceasbees revo ae ase eoaeans 4 2 1 MRS COMET CLC WV OS E S dee aie Sees is esa eee bees osc ee eect Seats aks acne ee AS Penpheral EguipMe til seere ena EA EEA EAE A A ARA 4 3 1 4 3 2 4 3 3 4 3 4 4 3 5 Molded case circuit breaker MCCB residual current operated protective device RCD earth leakage circuit breaker ELCB and magnetic contactor MC cccccccccccccceceeeeeeeeeeeeeeeeeees SWE Killers 6 cel Wn 07 6 Meme atte en ane ae ORR eee ene ee ee a ni nea ee a PNIU CSU CUS ea a O a E ueudwacdarea aa Ra onaan E mae SUC ADS DO Rc ene ene RO Ree aE ER PRE Ree ene mE en error E eer ee eae eae re eee Filtering capacitors suppressing AM radio band noises ccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees da CNS CUT ODON faeces east gs cs easiest a ea eatin esis catia tae cutest e ae TE 4 4 1 Peripheraleguipment OPUOMS sigs nas i cine ease ean eda ceeen ae eee ee ee 4 4 1 1 Braking resistor DBR and braking unit cccccccceeeeseeessseseesseessessssessssssssssessssssessseeeaaaas 4 4 1 2 Power regenerative PWM converter RHC Series cccseseesssseesseesseeesseessesseseessessesseesaaas BAN TIC Tears DC ING x sdicstiataoacs neat eats adedunsiowaiaunabelants EEEE r eae seabird aS sates aes AALA ACTIC ACR S acusie besten st a shaban atta dl a a a a AAV Sure SUDPECSSION u
28. 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 Chapter 5 FUNCTION CODES This chapter contains overview tables of 12 groups of function codes available for the FRENIC MEGA series of inverters function code index by purpose and details of function codes 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 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 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 MEH448 for details 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
29. GRAMS FOR CONTROL LOGIC 6 1 Symbols Used in Block Diagrams and their Meanings 00 0 0 cccccceescceceeceeeeeeeeeeceeeeeececeeeeeseseseseesssseeees 6 1 62 iDrive Frequency Cominand Blok r a A E A 6 2 6 Driyo Command BIO kE renat e css sah pated a ane OE T de Dec eaetnactades 6 4 0A A OnTor BIOG keer O A O A A A E Ov 6 6 EEE V E OO a AE a en ne aoe MP Reed E A NA 6 6 A2 Vector control with Speed sensor iho i a A 6 8 OS PID Process Contool Blokos somea etalon bo Re eotes donde neo eee 6 10 6 6 PID Dancer Control Block cesar cin a a 6 12 Gale SETAC Om EC O se octet tees ae ares eee eeaeacn ne onaed deem an eee ees 6 14 Chapter 7 KEYPAD FUNCTIONS OPERATING WITH THE KEYPAD 7 1 LED Monitor Keys and LED Indicators on the Keypad cccccccccccccccseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseessseeees 7 1 ded ONEINIEW OF Operation Modos eeraa a fxaased siadibaeadiadisedt hactansead a 7 4 Wed RUNDE IMIOG C s secsctheccatadetcatei a a dinate a a a tO eceses ous tensed none Mearelies 7 6 Poel Monitonne the Mnamo SAUS aane iay eTEN EE R a TE EE tu eetteaiaw 7 6 Taa Montonne HeRtalal M Seesen a a a a 7 8 J33 Seting p Tequency and PID commands siisreshiianieii eani e e a aE a 7 9 KoA Ronna stoppin he Molo aidsia a hated eis a e 7 14 Por Jose Opera oser E a e a a nO eee ee 7 14 ROG Remolie and local Modes csrsrmerenisre e a a 7 15 kal Extemalrunfreguency commandes e a r eE E 7 16 TA Proar MO deoe a a a a et a o ee ner eee ee eee 7 17
30. M converter RHC series Grounding terminals for the inverter s chassis or case and motor Earth one of the terminals and connect the grounding terminal of the motor Inverters provide a pair of grounding terminals that function equivalently Power supply 10 VDC for frequency command potentiometer Potentiometer 1 to 5kQ The potentiometer of 1 2 W rating or more should be connected 1 The frequency is commanded according to the external analog voltage input e 0 to 10 VDC 0 to 100 Normal operation e 10 to 0 VDC 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 3 Hardware specifications e Input impedance 22kQ e The maximum input is 15 VDC however the voltage higher than 10 VDC 1s handled as 10 VDC e Inputting a bipolar analog voltage 0 to 10 VDC to terminal 12 requires setting function code C35 to 0 2 10 2 3 Terminal Specifications Symbol Functions Analog setting 1 The frequency is commanded according to the external analog current input current input C1 function 4to 20 mA DC 0 to 100 Normal operation e 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 limi
31. O aj Keypad 5 PO Enclosure Control Circuit RE NQ Main Circuit Onenabl Z Ti inal Block di i Terminal pana e erminal Bloc AT 4 Block O R fa NN 3 Z Main Circuit aa O Terminal Block O D gt a FRN11G1S 20 b FRN30G1S 20 Figure 1 5 Terminal Blocks and Keypad Enclosure Location Auxiliary Control Power Control Circuit Input Terminals Terminal Block i ll sable rpctr P L A Fatma a E l Fi Power Input J Terminal Block inverter Output Terminal Block Terminal Grounding Power Input Dig Grounding Terminals Terminal Terminal Block DC Reactor and DC Bus Terminal Block a FRNO 75G1S 20 b FRN30G1S 20 Figure 1 6 Enlarged View of the Terminal Blocks Note A box LJ in the above model names replaces A E J or T depending on the shipping destination L Refer to Chapter 2 SPECIFICATIONS for details on terminal functions arrangement and connection and to Chapter 4 Section 4 2 1 Recommended wires when selecting wires FC stein Fuji Electric 13916183699 021 60510862 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 LU Refer to Chapter 3 SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES for details After selecting the rated capacities select appropriate peripheral equipment for the inv
32. OUGINC 7 SC UCB Sonin aa as T aR eae eal ce he a pce nee 33 3 5 3 4 5 3 5 5 3 6 Fol Enterme arun command essan a a aa a a a Sarno SCOP Pie the ANOLON asker ceed iiaae e ENERE cena EEEE EN E E E neta etones Specifying the acceleration deceleration time mode and pattern eseeeeeeeeeeeeeeeeeeeeees Adjusting The TUNMING PETLOTMAN CE serae E i A a eldphiwiad tiniugeadieeass Controlling MEMO saso T T RE A R a 5 3 7 1 Motor drive control to be selected cece ccc csccsccssccscesccsccsccescescescescescesscsscescescescesccescescescescs Dn VIMIOLOR COMSTAIIIS TO De Sel rataeaes cere askacc hacen tubes ea a ihasdbasaketedacieseken 5 3 8 5 3 9 5 3 10 5 3 11 S212 5 3 13 Sene ap Wy Os Ceram LS ah Gc cl a E le ae a OU UES MONKored daid riaren en E tesa ade yaarsnan EAA A Keeping om runnin the Motor srirsescs tyin oleh codes EE EE EE AE E as natioueeedees tees OUTS stas S10 1A IS ecient asradacOinseseatsaardanciesnaawwadodastiaicanners sande snseapsadvdanMacmacstsadeesneboemskepsadedastlawees Running in various operation MOES cccccccccccccceseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeEEEEEEEEEEE EE EEE EE EEE EEE Setting up controls suited for individual applications ccceeeseessseeccceeececeeeececeeeeeeeeeeeeeeeeeeeeeeeees GL Dt LOOP COnN O 525 telesales a a 5235132 PID Process CONO r e se Sinccta ts ae ieee 53 13 35 PND GanCer COmt Ol enia come iaacteat eeinaauactoan somee ccs ea eandae de caee eae
33. TRODUCTION 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 kE tes ANAM INS AE T A eon eats Goan Roa anes 1 1 K COMMONS VSte Iie epee E seta E E E E A 1 12 eZ CORY OL Ay CECE oes acces tesesasa E S a a cal eee 1 12 L Mootor dve CONTO 25 tisbes cto secoe aa A E e EDS 1 13 13 External Viewand Terminal BIOCkS ennio aa 1 14 L4 Recommended Conhionrati oM ensnare Ea oe N 1 16 1 1 Features 1 1 Features 2 D Q O Best vector control for the general purpose inverter in the class E 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 S n Current response 500 Hz SS Torque accuracy 10 a N VOAW OINSdsA OL NOILONQGOY HLNI The option card is required The above specifications may vary depending on the environment or conditions for use E Maximizing the performance of a general purpose motor Vector control without speed sensor available soon Useful for the application that requires a high starting torque such as the gondola type multi level car parking tower Speed control range 1 200 p Speed response 20 Hz po
34. V class series HD and LD mode inverters Tye FRN___GiSam ___ 04 o75 15 22 a7 55 75 1 5 ws 2 Olav oo pogramu Tw os fors 1s faa ar ss rs u Tie feel a To or os os T7 w w e 17s 1 ves 22 30 or a5 ss 75 00 Rated capacty HD 11 19 20 aa oe 10 14 18 24 co os or oo 05 1 VA io e e 2 a 2 2s as as or oo es 14 raa Rated voltage V a Three phase 380 to 480 V with AVR function sanna LH 1s 28 40 ss oo espesas o oo oo re 0 severe Foo T T T es aos or as eors or a 180 176 m 150 1 min 200 3 0 s jia ee 120 mi 2U o1 min Voltage frequency 380 to 480 V 50 60 Hz o a Allowable voltage frequency Voltage 10 to 15 Interphase voltage unbalance 2 or less 5 Frequency 5 to 5 Required capacity with DCR kVA 6 ee E mes o Joja S S ouy ooo MOPS TS Ts Tete ts fe PS a0 ip ee ee E Sa A E Applicable safety standards UL508C C22 2No 14 EN61800 5 1 2003 Applied Enclosure IEC60529 IP20 UL open type IPOO UL open type Cooling method race ieee Oa fra 20 2e 30 s2 e5 70 70 es es ele ule 2 Output ratings D a n 1 Fuji 4 pole standard motor 2 Rated capacity is calculated assuming the rated output voltage as 220 V for 200 V class series and 440 V for 400 V class series 3 Output voltage cannot exceed the power supply voltage x Ma vee A eee Three phase average vol
35. ase 400 V class series HD and LD mode inverters nnnnnnnnnnnnnensesseesrererrrerrrerrreeren 2 2 Dee COMON CHIC a IONS oroesi en iio EENE E E ET EAr a E EE EAEE ess eae 2 3 2o Tae e aa E E E E EE ee eee ence ee eee 2 10 2al Terminal fUnCtHoONS siccccrtaitivasnsrenncosisesooiabansanihetlevetnaatounss baideasnbaadiarabytonasciaa tad shuenscadinenitgtassbinntiasadaadwies 2 10 2 3 2 Terminal arrangement diagram and screw SpecifiCcatiONs ccccccccccccccccceceeeceeeeeeeeeeeeeeeeeeeeeeeeeeees 2 22 Lol Man Ci CUE Te CMAN lE omenie EEE E rE EEE a a 2 22 23242 ACOMUL OMI CIV terminals cssc S RE 2 24 2 4 Operating Environment and Storage Environment cccsssssssssssesssssssssssssssssssssssseeeeeeeeeeeeeeeeeeeeeeaes 2 25 2 4 1 Operating CNVITONMeEN ccccccccccccecceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeEEESEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EEE EE 2 25 2AL Monate Cy ROMAIN soinen a nE E En a EE E 2 26 2421 WOT ORAL SUO TAS coiere r e e ee Eae Eaa Ne NEE 2 26 Dens LONC EO SON Oe ranae a a E E E EE 2 26 23 Precautions tor Usine INV C1618 erinnert ena E E E EEEE RO iOi 2 27 ZS Precautions in introducing MV CLECIS yc cepccins cas ceanseduavesiednextnsata asdednetdisledua esieiuerdecetnaraunccayaebeatevedanceas 2 27 2 5 2 Precautions in running INVETTCTS ccc cece cece cece cece eee eeeeeeeeeeeeEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE EERE EEE 2 32 2 5 5 Precautions musine special Motors xe cc5 ice cetiss eck ccca iec
36. ation prevention control Dew condensation When the motor is stopped current is automatically supplied to the motor to keep the prevention motor warm and avoid condensation Customized logic Available in 10 steps with the functions of 2 input 1 output logical operation and timer interface function Available under V f control Available under dynamic torque vector control Available when the slip compensation is made active under V f control Available under V f control with speed sensor PG option required Available under dynamic torque vector control with speed sensor PG option required Available under vector control without speed sensor Available under vector control with speed sensor PG option required Not available in the initial version of inverters 2 6 Display Protection Running Stopping Life early warning Cumulative run time Trip mode 2 2 Common Specifications Speed monitor reference frequency output frequency motor speed load shaft speed line speed and speed indication with percent output current A output voltage V calculated torque input power kW PID command value PID feedback value PID output load factor motor output kW torque current 6 7 magnetic flux command 6 7 analog input and input watt hour The life early warning of the main circuit capacitors capacitors on the PC boards and the cooling fan can be displayed An external output is issued
37. bus capacitor electrolytic capacitors on printed circuit boards or cooling fans PTC thermistor activated 47 Inverter life Cumulative run time Inverter life number of startups Operates when the inverter output goes beyond the instantaneous overcurrent limiting level and avoids tripping during acceleration and constant speed operation When the motor is tripped and stopped this function automatically resets the tripping state and restarts operation line and ground Command loss A loss breaking etc of the frequency command is detected to output an alarm and the detection operation is continued at the preset frequency set at a ratio to the frequency before detection Momentary power e A protective function inverter stoppage is activated upon a momentary power failure failure protection for 15 ms or longer e If restart upon momentary power failure is selected the inverter restarts upon recovery of the voltage within the set time Installation location Shall be free from corrosive gases flammable gases oil mist dusts and direct sunlight Pollution degree 2 IEC60664 1 Indoor use only Surrounding 10 to 50 C 10 to 40 C when installed side by side without clearance 22 kW or temperature below Relative humidity 5 to 95 RH without condensation Vibration 200 V 55 kW 400 V 75 kW or below 3 mm 2 to less than 9 Hz 9 8m s 9 to less than 20 Hz 2 m s 20 to less than 55 Hz 1m s 55 t
38. ct a DC REACTOR introduced in this manual For use of the other reactor please inquire of us about detailed specifications Japanese Guideline for Suppressing Harmonics by Customers Receiving High Voltage or Special High Voltage Refer to this manual Appendix B for details on this guideline Safety precautions Read this manual and the FRENIC MEGA Instruction Manual INR SI47 1183 E INR SI47 1223 E 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 Safety precautions are classified into the following two categories in this manual AW ARNING Failure to heed the information indicated by this symbol may lead to dangerous conditions possibly resulting in death or serious bodily injuries Failure to heed the information indicated by this symbol may lead to ACAUTION dangerous conditions possibly resulting in minor or light bodily injuries and or substantial property damage Failure to heed the information contained under the CAUTION title can also result in serious consequences These safety precautions are of utmost importance and must be observed at all times ACAUTION This product is not designed for use in appliances and machinery on which lives depend Consult your Fuji Electric representative before con
39. de switch SW4 on the control PCB and changing data of the function code F29 You can select one of the following signal functions with function code F31 e Output frequency e Output current e Output voltage e Output torque e Load factor e Input power e PID feedback amount Speed PG feedback value e DC link bus voltage Universal AO e Motor output e Calibration e PID command e PID output Input impedance of the external device Min 5kQ at 0 to 10 VDC output I aS 75 Sg O Analog output While the terminal is outputting 0 to 10 VDC it is capable of driving up to two analog voltmeters with 10 kQ impedance Input impedance of the external device Max 500Q at 4 to 20 mA DC output Adjustable range of the gain 0 to 300 FMA 11 Analog common Two common terminals for analog input and output signals These terminals are electrically isolated from terminals CM s and CMY FMP Pulse monitor Pulse signal is output You can also select one of the signal FMP function functions listed in the above column for FMA using function code F35 Input impedance of the external device Min 5kQ While the terminal is outputting 0 to 10 VDC it is capable of driving up to two analog voltmeters with 10 kQ impedance Pulse duty Approx 50 Pulse rate 25 to 6000 p s at full scale Voltage waveform e Pulse output waveform 15 0 V ta 16 5 V e FMP output circuit Pulse output CM Digital common
40. e displayed after the stop S78 Protection a at Start check If the running command is being ordered when switching the running command method from power on alarm reset or the linked operation the operation starts suddenly This function bans running and displays 4 Tuning error Stop the inverter output when tuning failure interruption or any fault as a result of tuning is detected during tuning for motor constant RS 485 communications error port 1 Speed mismatch or excessive speed deviation 4 to 7 Data save error upon When the undervoltage protection function works an alarm is displayed if the data is not _ Lis undervoltage properly saved RS 485 Stop the inverter output detecting the communication error between the inverter main unit communications error and a mate when the RS 485 connection port of the touch panel is used to configure the EnA port 2 network Hardware error Stop the inverter output detecting the LSI abnormality of the print board for power supply _ which is mainly caused by noise EI Simulated alarm is output by the keypad operation ocr ILII PID feedback wire Stop the inverter output detecting a breaking when the input current is allocated to the PID _ break control feedback Select valid invalid Leu 4 Available under V f control with speed sensor PG option required 5 Available under dynamic torque vector control with speed sensor PG o
41. eae 5 3 14 5 3 15 5 3 16 Customizitie Ine keypad seinna a A owed oucad tulgs eee ess teeetoass Controlling the inverter via communications line cceeeeseeeeessesseseeeeeseseeeseeeseeeeeeeeeeeeesseesenaas Activating the protective functions iier cere elie ere ere eases ice bbe eet ati Ol ohn SLOL Protection or machinery Witi MeS esai a A a daar 5 39 SoG PEOCECHION O1 MOTOI Seenaa ae a a a Tieeguadeet 5 39 5 3 16 3 Using other protective and safety functions c cc ccecccccsccecceeeeececeeeecceceeececececeeeeeeeeeeeeeeeeeaeees 5 40 Sel sNiaWle mane a a N a a a N A 5 42 SII Maintenance OliMVerters sns ieor a A E 5 42 SA2 Maintenance of Machinery isso Sd Sac pk a E E E E E E E E 5 42 SA Detalo Foncion E odos asire E E T A ASE 5 43 SAL Fecodes Fundamental Tun CH Ons icc ted hs secad aana EEEE E E E 5 43 54 2 E codes Extension terminal TUnCHONS Jersie asni REE eer i EE EEEE REEE alesse ese caw 5 91 DA C codes Control MI CLIOIIS kancra aaa a a a a a 5 128 SAA PsCodes Motor parameters erea a a A E A A A A 5 133 54 5 Heodes Higeh performance functions Firestone a n E lcd 5 138 5 4 6 A codes Motor 2 parameter b codes Motor 3 parameter r codes Motor 4 parameter 5 174 SA Jeodes Apphcatonrmnctons T eserine ar e E E E ea 5 177 54S Aecodes Application functions 2 32s dis AA RGAE A 5 194 SAD COMES CMs IUNCHONS hiersie alessio sa a alec din cabooses E vache veh ashen ake Mites es 5 199 Chapter 6 BLOCK DIA
42. ecescessecsteceseceteceseseesesesseeseeesecesecesececeseesensses 7 46 TO USB 6 a1 a1 21 ia garment ee eT oe ee ee ee a a 7 48 yii Chapter 8 RUNNING THROUGH RS 485 COMMUNICATION Sak OVERVIEW Ol RS 4 850 OmmIUICA IO Msn coat sceser teats a a a a e anid eeinectaaas 8 1 8 1 1 RS485 COMMONSPECITICATIONS j 5 52225 sas chetarctase dees doetaswy ace dee eaecack padees Seetaseeacaceae see tasceaatadees seotacen nace 8 2 8 1 2 Terminal specifications for RS 485 COMMUNICATIONS ccceeeeeeeeeeessesesseeeseeseeeeseseeseesseseseeeeeeeeens 8 3 Behe AC OMNEC OMAN LOG crus rrocheutqmcuetionanstegannnaavsvans neustaemeiel sauna onus sande euononeuel sodas vonononecrann dene tauaryaen Goan 8 4 SLA COMMUNICATIONS SUPPO device Susman eee ate cee eee ate eee 8 6 Salo INOISSSUPPICSSIO Nc ai s a ee ee 8 7 S2 OVerViCW OF PRR NIC NWO dd Cl cear aE E E tenseeiaemeessnal tienen saetes 8 8 Beds Spec eano Se Geet aa ptosis Pte aa a ences bat ys a Seaweed a Somes a e a a semen bees 8 8 Bee SCOMME Osoon a a a arts an fomteemascteatuasetenaunce 8 9 BD SE MMIC EI OMM ONCE VIC Wicd atts Sesser a a eon sinauta eas aeaaa ulead Aanaiauiiausas 8 9 Sok Seine OF CoN COC anene a asad are as sae 8 9 aie amma 81 6 OU 6 a E rere Er opmm ea nr cnr ry A notre nr 8 10 B25 RUNNA STACIS MOM IGOR asolar n a a aiedanaaei adn aie 8 11 S2 A TESEN Af ee eee ee eee eee Ree ene ee ee eee Se ne eee nee eee ee ee eee Teen 8 12 8 2 3 5 Real time trace Display
43. eleration deceleration weak free strong curvilinear acceleration deceleration acceleration deceleration maximum capacity of constant output Deceleration mode coast to stop Shutoff of the run command lets the motor coast to a stop Forcible stop deceleration time Deceleration stop by the forcible stop STOP Auto tuning by shortest acceleration deceleration mode and optimal acceleration 8 deceleration mode Available under V f control Available under dynamic torque vector control Available when the slip compensation is made active under V f control Available under V f control with speed sensor PG option required Available under vector control without speed sensor Not available in the initial version of inverters 2 4 2 2 Common Specifications fen Remark Frequency limiter e Specifies the high and low limits in Hz Upper limit and lower limit frequencies e It is possible to choose the operation done when the set frequency drops below the lower limit from between continuous operation at lower limit frequency and operation Stop Bias frequency e Bias of set frequency and PID command can be independently set setting range 0 to 100 Analog input e Gain Set in the range from 0 to 200 e Off set Set in the range from 5 0 to 5 0 e Filter Set in the range from 0 00s to 5 00 s Jump frequency e Three operation points and their common jump width 0 to 30 0 Hz can be set Jogging op
44. eration e Operation with Gun key standard keypad Fwd or fev key multi function keypad or digital contact input FWD or REV Exclusive acceleration deceleration time setting exclusive frequency setting 2 gt 3 N SNOILVO IldJIOJdS Auto restart after e Trip at power failure The inverter trips immediately after power failure momentary power e Trip at power recovery Coast to stop at power failure and trip at power recovery failure e Deceleration stop Deceleration stop at power failure and trip after stoppage e Continue to run Operation is continued using the load inertia energy e Start at the frequency selected before momentary power failure Coast to stop at power failure and start after power recovery at the frequency selected before momentary stop to 3 e Start at starting frequency Coast to stop at power failure and start at the starting frequency after power recovery 1 to 3 Hardware current Limits the current by hardware to prevent an overcurrent trip from being caused by fast z limiter load variation or momentary power failure which cannot be covered by the software E current limiter This limiter can be canceled S Operation by e With commercial power selection command the inverter outputs 50 60 Hz SW50 commercial power SW60 1 to 3 supply e The inverter has the commercial power supply selection sequence Slip compensation Compensates for decrease in speed according to the load 1 to
45. erter then connect them to the inverter L Refer to Chapter 4 SELECTING PERIPHERAL EQUIPMENT for details on the selection of peripheral equipment Figure 1 7 shows the recommended configuration for an inverter and peripheral equipment Three phase power supply Molded case circuit breaker MCCB or Earth leakage circuit breaker ELCB r aA with overcurrent protection Magnetic contactor DC reactor 55 kW or below Provided as option 75 kW or above Provided as standard An inverter with a capacity of 55 kW or above in LD mode is equipped with a DC reactor as standard Braking resistor General purpose motor or Fuji motors exclusively designed for vector control Figure 1 7 Recommended Configuration Diagram FO Eten Fuji Electric 13916183699 021 60510862 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 product warranty precautions for using inverters external dimensions examples of basic connection diagrams and details of the protective functions Contents Dek SPARC ARC VIO OCIS ace asactoadaselsboecmsdaneedacnassaiesdasoctecdehce A E A EA A A E E 2 1 2 1 1 Three phase 200 V class series HD and LD mode inverters nnnnnnnnnnnnnnensnerersrererrrsrrrrrrrreeren 2 1 2 1 2 Three ph
46. fan with ON OFF Display of inverter lifetime alarm compensation Total run time of the electrolytic capacitor on the printed circuit board 1 9 Consideration for environment E 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 MEGA resistance to the environmental impact has been increased compared with the conventional model FRENIC5000 G11S P11S However examine the use of the inverter carefully according to the environment in the following cases a Environment is subject to sulfide gas at tire manufacturer paper manufacturer sewage disposer or part of the process in textile industry b Environment is subject to conductive dust or foreign matters in metalworking operation using extruding machine or printing machine waste disposal c Others The inverter is used in the environment of which specification exceeds the specified range If you are examining use of the inverter under the above conditions consult us regarding the models with enhanced durability E Protection against micro surge optional Surge suppression unit SSU optional If the motor drive cable is long a very thin surge voltage micro surge is generated at the motor connection ends This surge voltage cau
47. gnal outside the inverter for protecting the braking circuit E 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 6 S curve accel decel range setting 7 Detection of a PID feedback wire break MEGA World Keeps Expanding PG option card for positioning control available soon The customized logic interface function is adopted in the inverter body Available soon Logic input output can be easily created by parameter setting This makes it possible to simplify the peripheral circuits This control function is best suited for the application that requires ECLB MC k at 2 ne highly accurate positioning such as that of the conveyance or Ei meca 4m machine By combined use of the position control device APR and PG vector control the position control accuracy has been remarkably improved Shortened positioning time by this function will be helpful to reduce the tact time of a cycle Example Fixed length marking system Fores Object to be marked Moving direction Balt std 22 S gt gt Position con control se section ae point p Reference position
48. he 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 Do not apply a voltage of 7 5 VDC or higher to terminal C1 Doing so could damage the internal control circuit z S ON 3 lt Figure 2 2 Connection of Shielded Wire Figure 2 3 Example of Electric Noise Reduction 2 12 2 3 Terminal Specifications Digital Inout Terminals uo 2 Name Functions D Digital input 1 1 Various signals such as Coast to a stop Enable external a alarm trip and Select multi frequency can be assigned to Digital input 2 terminals X1 to X9 FWD and REV by setting function N seen codes E01 to E09 E98 and E99 For details refer to Chapter ae Digital input 3 5 FUNCTION CODES O Digital input 4 2 Input mode 1 e SINK SOURCE is changeable by using the 5 slide switch SW1 Refer to Setting up the slide switches on gt Digital input 5 page 2 20 5 ai ea 3 Switches the logic value 1 0 for ON OFF of the terminals Digital input 6 X1 to X9 FWD or REV If the logic value for ON of Digital input 7 the terminal X1 is 1 in the normal logic system for example OFF is 1 in the negative logic system and vice versa Digital input 8 Digital input terminal X7 can be defined as a pulse train input terminal with the function codes Digital input 9 Maximum wiring length 20 m Maximum input
49. iable setting LD mode 630 kW Note Frequency drops automatically to protect the inverter depending on environmental temperature and output current This auto drop function can be canceled Setting range SNOILVOlsIOAdS Output frequency Analog setting 0 2 of maximum frequency at 25 10 C 1 accuracy Stability Keypad setting 0 01 of maximum frequency at 10 to 50 C Setting resolution Analog setting 1 3000 of maximum frequency 1 1500 with V2 input The resolution can be set in the function code 0 01 to 500 Hz Keypad setting 0 01 Hz 99 99 Hz or less 0 1 Hz 100 0 to 500 Hz Link setting 1 20000 of maximum frequency or 0 01 Hz fixed Output frequency Speed control range Minimum speed Base speed 1 1500 4P 1 r min to 1500 r min 7 Minimum speed Base speed 1 200 4P 7 5 r min to 1500 r min 6 Minimum speed Base speed 1 100 1 200 4P 15 r min to 1500 r min 1024 p r 4 t5 Constant torque range Constant output range 1 4 7 Constant torque range Constant output range 1 2 4 5 6 Speed control accuracy Analog setting 0 2 of maximum frequency at 25 10 C 4 5 7 Digital setting 0 01 of maximum frequency at 10 to 50 C Analog setting 0 5 of base speed at 25 10 C 6 Digital setting 0 5 of base speed at 10 to 50 C Control method V fcontrol 1 Dynamic torque vector control 2 V f control with slip compensation active 3 V f control with speed sensor PG op
50. ime This improves the operation efficiency of machinery such as cutting machines or carrier machines Current overload durability 200 for 3 seconds and 150 for 1 minute The standard model is available in the following two drive modes concerning the operation load Current overload durability Major application HD High duty mode 200 for 3 sec 150 for 1 min Operation under heavy load LD Low duty mode 120 for 1 min Operation under light load E Quicker response to the operation commands The terminal response to the operation commands has had an established reputation The FRENIC MEGA has further shortened this response time achieving the industry top response time This function is effective in shortening the tact time per cycle and effective for use in the process including frequent repetitions Example Terminal response time 7 Output example per command i Approx Ams curen 2 PAO O P i FRENIC MEGA Approx 4 ms Conventional inverters Approx 6 ms L Response start Response time shortened by approx 2 ms Control terminal signal Run command m Expanded capacity for the brake switching circuit built in type A brake switching circuit is built in inverters with a capacity of 22 kW or less as standard These inverters are applicable to vertical carrier machines and others that run with a certain regenerative load Inverters with a capacity of 7 5 kW or less also integrate a braking resistor
51. ing running status of an inverter in waveforms s00eseseeeeees 8 13 6 2 5 0 Historical trace Availale soon keare a ei ccs ecadceto EE EEA ee ees 8 14 62 57 cUSBport onm the standard keypad ernaria A A E A A E EAT OOE 8 15 Chapter 9 TROUBLESHOOTING 90 Protective Tunc HONS i a a a e e a e e bodeutuensuetad rece 9 1 9 2 B f re Proceeding with Troubles nO Os e iasrnie ii a Eaei 9 3 9 3 IfNeither an Alarm Code Nor Light Alarm Indication 1 Appears on the LED Monitor 9 4 Sr Abnormal Moor OME GAUIOM 355553 i5585 a0 A EAA EE E ETEA E 9 4 932 Problems with inverter Seinos amini aa E E A E E EA 9 10 9 4 Ifan Alarm Code Appears on the LED MOmitor cccccccccccccccccccsseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeees 9 11 9 5 Ifthe Light Alarm Indication 1 4 Appears on the LED Monitor cccccccccscscsesssessseseseseseeseseeeeeees 9 25 9 6 Ifan Abnormal Pattern Appears on the LED Monitor while Neither an Alarm Code nor Light Alarm Indication i is Displayed ccicieisscssccsctscosascsonvsrsuvoossscensossonevesstocssssvasearossvaessoseoseas 9 26 Appendices App A Advantageous Use of Inverters Notes on electrical nNOiSe c c csssssssesessssesssssssssssssssessssseeeeeeeeeeaas A 1 Al BTCeE OL MVerers om other devices aea e Ea E E A 1 A2 NOO eaa A O TI E ENA AT EA E eine eal eme eee A 2 An Nore preventi oerna Ea E E ee ee ee ear ee A 4 App B Japanese Guideline for Suppressing Harmonics by
52. ment and European Council limits the use of specific hazardous substances included in electrical and electronic devices VOAW OINSdsA OL NOILONGOUYLNI Global compliance E Application to global standards pending EC Directive CE marking UL standard cUL certified C Uy us LISTED FC ate Fuji Electric 13916183699 1 11 021 60510862 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 The PWMed frequency is called the Carrier Frequency lt Main circuit gt Converter 1 Power supply DC link bus Motor Frequency Accelerator d decelerator comman processor voltage processor Figure 1 1 Schematic Overview of Theory of Inverter 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
53. ncy 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 3 Ti ji re fF i ti i i A i ae a ou p i na ka mi AE e 7 7 7 7 FN i i Y N f i i if Mi a hae i YY a hive T n T mit i p z j j 1 7 i a Wn Wien F 1 1 Features E Dancer control function optimum for winding control 2 2 Q The PID value calculated by comparing the feedback value with the speed command value is added to or subtracted from the reference speed Since the PID processor gain in proportional band can be set low the inverter can be applied to automatic control systems requiring quick response such as speed control p b Winding machine A Fixed roll Fixed roll Upper limit Rotation speed contro Dancer roll Reference position Position information VOAW OINSdsA OL NOILONGOUYLNI ex 0V to 10V Potentiometer etc Line speed is adjusted according to the position of the dancer roll Lower limit Thorough protection of the braking circuit The inverter monitors the braking transistor operation status to protect the braking resistor Upon detection of a braking transistor abnormality the inverter outputs an exclusive signal Provide such a circuit that shuts the input power off upon receipt of the exclusive si
54. ni SoU naaa e E a E S AA NG Output Circuit ers OLS i e a E nG aes 4 4 1 7 Zero phase reactor for reducing radio noise ACL ssssssssssssesnseenensenesereereesssrerererrrerrrerrreren 4 4 2 Options for operation and communications sssssssesseseeeeeeserererrrrrrrrerrrrrrrrrrrrrrrrrrerrrrrrrerrrrrrrrrreeees 4 4 2 1 External frequency command potentiometer cccccccccccccccceeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeees 4 4 2 2 Extension cable for remote operation merreni a A AAN E E MAZ verter support loader SOL Al Ea a tan Gn eae JAA PO mteracecard OPON asaini a a ema 4423 Relay Output card Option ei a ol A EAA EA E ied ied Ste eae 4 4 3 Meter opon eaei a N Pn Ee CMC Gy Ne 1 bs aa a E vee iea teed cucuunasiencueant Chapter 5 FUNCTION CODES D gt VOVerview OF FUNCTION CodeS sasni a a a a Oe Pe OE ode aE a a A TE E T E TEE A E E So Funcion Code index by Purpose e a AGA a Gikeass 5 3 1 5 3 2 Configuring the minimal requirements for the inverter to just run the motor ceceeeeeseereeeeees nie HTT Oy S161 Og aT Sh AG a1 9 Le hey aReeneamn mre ee eh ent Onno eee nr Renee ee See nr Tee tone at nee ee AY Crem om frie rete ve 53 2 Frequency Scttime trom the Key pad oi parascctcicasadsanthevenresnnsserssderseeeenedeeatieworennemeussiaueanadeiaeleleens 5 32 22 Prequency setine by analog IPsec cas danieas tenchanesinctanseideideotecestensheluete Batt teee sca a tt cach canine Doe 8 Other TRC
55. niaeaansayaeon A seen tease Gunter EEE 2 32 2 6 External Dimensions cscscssudssnnesasageatmobadvacuaasidatannehatnbesanaamvuvsioasuassbaucdeoehatonnnahgaesaneipebebasetearasuesaaaioarsbonseces 2 34 PA A EE E E E E EE E E E E A E E A E 2 34 PAEA NSS AG E O AE O AIO O A T A A O N ANN E 2 38 2AT Comection Diap ees capcigentecetresapeneisacra cts oeernetat veasette estonia pereisarse aes bicin toads actin EEEE ENDE 2 39 2 7 1 Ru nning a Staal MOU OM senescence e a A E anes 2 39 2 7 2 Running a Fuji motor exclusively designed for vector control eseessesesennennnnnnenseeeeeseeresreserreeeeee 2 41 28 Froe Ve UN OI E AO EOE i 2 43 2 1 Standard Models 2 1 Standard Models 2 1 1 Three phase 200 V class series HD and LD mode inverters tend a e SSCS Type FRN___G1Sax oa ove 1s a2 a7 ss 7s5 1 msl ml oll s os rw Tio T 1 1 7s 1 ps res 2 20 a7 os ss 75 Rated capaciy wa HO 11 1o 80 42 ee 10 we 24 28 a5 o5 oo or 2w e e gt 2 25 0 ss oe ot 107 Rated voltage V 3 Three phase 200 to 240 V with AVR function aa AVR faolion 230 V se EAKA OA CAAA Rated current A 4 7 31 8 46 2 59 4 748 88 115 146 215 283 29 42 55 68 80 107 e 150 1 min 200 3 0 s Overload capability Allowable Allowable voltage frequency ai 10 to 15 Interphase voltage unbalance 2 or 5 Frequency 5 to oh Required capacity _ 12 22 34
56. nstant torque load 1 to 4 Manual torque boost Torque boost value can be set between 0 0 and 20 0 1 4 Select application load with the function code Variable torque load or constant torque load 1 4 22 kW or below 200 or higher 30 kW or above 180 or higher reference frequency 0 3 Hz 6 22 kW or below 200 or higher 30 kW or above 180 or higher reference frequency 0 3 Hz Base frequency 50 Hz 2 Auto torque boost operation 1 to 4 Keypad Start and stop with Gun and gro keys Standard keypad Start and stop with Fo fev and 0 keys Optional multi function keypad External signals digital inputs Forward Reverse rotation stop command capable of 3 wire operation coast to stop command external alarm alarm reset etc Link operation Operation through RS 485 or field bus option communications Switching operation command Remote local switching link switching Keypad Settable with and V keys 1 to 5 VDC can External volume Can be set with external frequency command potentiometer 1 to 5 kQ be 1 2 W adjusted Analog input 0 to 10 V DC 45 V DC 0 to 100 terminals 12 and V2 arn and 0 to 10 V DC 5 V DC 0 to 100 terminals 12 and V2 analog 4 to 20 mA DC 0 to 100 terminal C1 input gain UP DOWN operation Frequency can be increased or decreased while the digital input signal is ON Multi frequency Selectable from 16 different frequencies step 0 to
57. o less than 200 Hz Storage humidity 5 to 95 RH without condensation 2 gt 3 N SNOILVOlsalIOAdS 2 3 Terminal Specifications 2 3 1 Terminal functions Main circuit and analog input terminals Classifi Main circuit Analog input cation Symbol L1 R L2 S P1 P P N DC link bus Name Main circuit power inputs Auxiliary power input for the control circuit DC reactor connection Braking resistor Auxiliary power input for the fans Grounding for inverter and motor Power supply for the potentiometer Analog setting voltage input Functions Connect the three phase input power lines Inverter outputs Connect a three phase motor RO TO For a backup of the control circuit power supply connect AC power lines same as that of the main power input Connect a DC reactor DCR for correcting power factor e HD mode inverters A DCR is provided as option for 0 4 to 55 kW and as standard for 75 kW or above e LD mode inverters A DCR is provided as option for 5 5 to 45 kW and as standard for 55 kW or above Connect the braking resistor option Connect a DC link bus of other inverter s A high power factor regenerative PWM converter is also connectable to these terminals Normally no need to use these terminals Use these terminals for an auxiliary power input of the fans in a power system using a power regenerative PW
58. odical collection of life information can be carried out efficiently The real time tracing function permits the operator to check the inverter for abnormality Example of use at the manufacturing site arene _ e E iss rer rss re A FRENIC loader Allows operation of the inverter connected on line with the PC Remote keypad Information can be written in the keypad memory 1 7 Network connectivity E Connectivity to the various FA networks with the following option cards available soon SX bus interface card T link interface card PROFIBUS DP interface card DeviceNet interface card CANopen interface card CC Link interface card E 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 With the terminal connection multi drop connection can be made easily RS 485 terminal enabling RJ 45 connector multi drop connection CEA AE RR CORI SS 2a ee ee me et e LE Lol St ae Ra ag Da El Ee ee Pe a a j E p 13916183699 021 60510862 1 8 1 1 Features Prolonged service life and improved life judgment function 2 Q mE 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
59. ower to the keypad through the pins specified for the port 1 below The extension cable for remote operation also uses keypad Standard RJ 45 wires connected to these pins for supplying the keypad connector power Remove the keypad from the standard RJ 45 connector and connect the RS 485 communications cable to control the inverter through the PC or PLC Programmable Logic Controller For setting of the terminating resistor refer to Setting up the slide switches on page 2 20 SNOILVOlsalIOAdS GND Terminating RJ 45 connector resistor l SW3 RJ 45 connector face pin assignment Figure 2 9 RJ 45 Connector and its Pin Assignment Communication Pins 1 2 7 and 8 are exclusively assigned to power lines for the standard keypad and multi function keypad so do not use those pins for any other equipment USB USB port A USB port connector Mini B that connects an inverter to a connector On the keypad personal computer FRENIC Loader software running on the computer supports editing the function codes transferring them to the inverter verifying them test running an inverter and monitoring the inverter running status FRENIC Loader is available as a free download from our website at http web1 fujielectric co jp Kiki Info EN User guestlogin asp Fuji Electric FA Components amp Systems Co Ltd Technical Information site On the Fuji website shown above select Technical Information Drive Control
60. ption required 6 Available under vector control without speed sensor 7 Available under vector control with speed sensor PG option required When the connection port of the keypad connected via RS 485 communication port to Zg i LI LI detect a communication error the inverter is stopped and displays an error Stop the inverter output when the speed deviation excesses the specified value difference _ between speed command and feedback cree 2 8 Protection Environment 2 2 Common Specifications Item Remarks Alarm relay output e The relay signal is output when the inverter stops upon an alarm for any fault e key or digital input signal RST is used to reset the alarm stop state Light alarm warning The light alarm display is indicated when alarm or warning matters set as minor troubles occurred The operation is continued Light alarm object Heat sink overheat Li External alarm 7 Inverter internal overheat L473 Motor protection 1 77 Braking resistor overheat 5 7 Overload of motor L to Lit T Keypad communications error 72 Option communications error 7 Option error 4 4 RS 485 communications error port 1 4 Speed mismatch or u L IIL excessive speed deviation E RS 485 communications error port 2 DC fan locked Motor overload early warning Heat sink overheat early warning Lifetime alarm DC link
61. pulse Run forward 30 kHz When connected to a pulse generator with open command collector transistor output Needs a pull up or pull down resistor See notes on Run reverse page 2 15 oa 100 kHz When connected to a pulse generator with complementary transistor output For the settings of the function codes refer to Chapter 5 FUNCTION CODES Digital input circuit specifications 3 lt Control circuit gt E PLC TA VOC E Bb A E C X1 to X9 wo REV 1 6kQ for X7 CM Figure 2 4 Digital Input Circuit Operating ON level OV 2V ee l SINK OFF ewi Operating current at ON 2 5 mA 5 mA Input voltage is at 0 V For X7 9 7 mA 16 mA Allowable leakage current Aoa o osma 2 13 I E 75 Sg Digital input Symbol PLC Name Functions PLC signal 1 Connects to PLC output signal power supply power Rated voltage 24 VDC Allowable range 22 to 27 VDC Maximum 100 mA DC 2 This terminal also supplies a power to the load connected to the transistor output terminals Y1 and Y2 Refer to Transistor output described later in this table for more Digital input Two common terminals for digital input signals COUIDE These terminals are electrically isolated from the terminals 11 s and CMY m Using a relay contact to turn X1 to X9 FWD or REV ON or OFF Figure 2 5 shows two examples of a circuit that uses a relay contact to turn control signal input
62. ses deterioration of the motor dielectric breakdown or increase in noise Using the surge suppression unit suppresses this surge voltage 1 The surge suppression unit significantly suppresses the surge voltage when simply connected with the motor 2 Since no additional work is required it can be easily mounted on the existing equipment 3 The unit is applicable to the motors regardless of their capacity However consult us for application to the motor with a capacity of 75 kW or over 4 The unit requires no power source and no maintenance 5 Two types are available One for 50m motor cable and the other for 100m motor cable 6 Compliant with environmental standard and safety standard Compliant with RoHS Directives and application to UL standard pending Surge suppression unit structure Surge suppression unit Z Zs lt Zm Zs Surge absorption 1 1 Features E Compliance with RoHS Directives 2 D Q O MEGA complies with European regulations that limit the use of specific hazardous substances ROHS as a standard This inverter is environment friendly as the use of the following six hazardous substances is restricted lt Six hazardous substances gt Lead mercury cadmium hexavalent chromium polybrominated biphenyl PBB and polybrominated biphenyl ether PBDE Except the parts of some inverter models lt About RoHS gt The Directive 2002 96 EC promulgated by the European Parlia
63. sidering the FRENIC MEGA series of inverters for equipment and machinery related to nuclear power control aerospace uses medical uses or transportation When the product is to be used with any machinery or equipment on which lives depend or with machinery or equipment which could cause serious loss or damage should this product malfunction or fail ensure that appropriate safety devices and or equipment are installed 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 It also provides descriptions of the operating and storage environment product warranty precautions for use external dimensions examples of basic connection diagrams and details of the protective functions 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 HD LD drive mode and motor drive control
64. t speed sensor 7 Available under vector control with speed sensor PG option required 8 Not available in the initial version of inverters 2 5 Control 2 3 4 5 6 7 8 Remark Automatic e Ifthe DC link bus voltage or calculated torque exceeds the automatic deceleration level deceleration during deceleration the inverter automatically prolongs the deceleration time to avoid overvoltage trip It is possible to select forcible deceleration actuated when the deceleration time becomes three times longer If the calculated torque exceeds automatic deceleration level during constant speed operation the inverter avoids overvoltage trip by increasing the frequency Deceleration The motor loss is increased during deceleration to reduce the regenerative energy in the characteristic inverter to avoid overvoltage trip 1 4 improved braking capacity Auto energy saving The output voltage is controlled to minimize the total sum of the motor loss and inverter operation loss at a constant speed With digital input signal auto energy saving mode can be turned ON or OFF by an external device control inverter lowers the output frequency to avoid overload s Cooling fan ON OFF Detects inverter internal temperature and stops cooling fan when the temperature is low control The fan control signal can be output to an external device 2nd to 4th motor settings Switchable among the four motors Code data
65. tage V GN Voltage unbalance x 67 IEC61800 3 If this value is 2 to 3 use an optional AC reactor ACR 6 Required when a DC reactor DCR is used A DCR is provided as standard for LD mode inverters with a capacity of 55 kW and inverters with a capacity of 75 kW or above 7 Average braking torque for the motor running alone It varies with the efficiency of the motor 8 380 to 440 V 50 Hz 380 to 480 V 60 Hz Q For inverters with a capacity of 55 kW a DCR is provided as standard or option for LD or HD mode respectively Note A box O in the above table replaces A E J or T depending on the shipping destination 2 2 2 2 Common Specifications 2 2 Common Specifications Item Remarks Maximum e 25 to 500 Hz HD mode V f control 1 2 3 3 5 frequency e 25 to 200 Hz HD mode V f control with PG vector control with PG 4 5 7 lt e 25 to 120 Hz HD mode vector control without speed sensor 6 LD mode various controls 1 to 7 Base frequency 25 to 500 Hz variable 120 Hz in LD mode Starting frequency 0 1 to 60 0 Hz variable Vector control without speed sensor 6 Vector control with PG 0 0 Hz 7 Carrier frequency 0 75 to 16 kHz variable setting HD mode 0 4 to 55 kW LD mode 5 5 to 18 5 kW e 0 75 to 10 kHz variable setting HD mode 75 to 400 kW LD mode 22 to 55 kW e 0 75 to 6 kHz variable setting HD mode 500 to 630 kW LD mode 75 to 500 kW e 0 75 to 4 kHz var
66. ter level setting or analog input monitor can be assigned to this terminal I g n N Sg D 2 gt 3 N SNOILVOlsalIOAdS 3 Hardware specifications e Input impedance 250Q e The maximum input is 30 mA DC however the current larger than 20 mA DC is handled as 20 mA DC V2 Analog setting 1 The frequency is commanded according to the external analog voltage input voltage input V2 function e 0 to 10 VDC 0 to 100 Normal operation e 10 to 0 VDC 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 Hardware specifications e Input impedance 22kQ e The maximum input is 15 VDC however the voltage higher than 10 VDC 1s handled as 10 VDC e Inputting a bipolar analog voltage 0 to 10 VDC to terminal V2 requires setting function code C45 to 0 PTC NTC Connects PTC Positive Temperature Coefficient NTC thermistor input Negative Temperature Coefficient thermistor for motor PTC NTC protection Ensure that the slide switch SW5 on the control function PCB is turned to the PTC NTC position refer to Setting up the slide switches on page 2 20 Analog input The figure shown at the right illustrates the internal circuit diagram where SW5 switching the input of terminal V2 between V2 and PTC NTC
67. tion 4 Dynamic torque vector control with speed sensor PG option 5 Vector control without speed sensor 6 Vector control with speed sensor PG option 7 Voltage frequency e Possible to set output voltage at base frequency and at maximum output characteristic 200 V frequency 80 to 240 V class The AVR control can be turned ON or OFF 1 4 series Non linear V f setting 3 points Free voltage 0 to 240 V and frequency 0 to 500 Hz can be set 1 4 Possible to set output voltage at base frequency and at maximum output 400 V frequency 160 to 500 V class The AVR control can be turned ON or OFF 1 4 series Non linear V f setting 3 points Free voltage 0 to 240 V and frequency 0 to 500 Hz can be set 1 4 Control Available under V f control 2 Available under dynamic torque vector control 3 Available when the slip compensation is made active under V f control 4 Available under V f control with speed sensor PG option required 5 Available under dynamic torque vector control with speed sensor PG option required 6 Available under vector control without speed sensor 7 Available under vector control with speed sensor PG option required 8 Not available in the initial version of inverters 2 3 Control 2 3 4 6 8 Torque boost Starting torque HD mode Start stop operation Frequency setting Acceleration deceleration time Remark Auto torque boost For co
68. uit gt SNOILVOlsalIOAdS Y X1 to FWD a With the switch turned to SINK b With the switch turned to SOURCE Figure 2 6 Circuit Configuration Using a PLC For details about the slide switch setting refer to Setting up the slide switches on page 2 20 oF T a Q E For inputting a pulse train through the digital input terminal X7 e Inputting from a pulse generator with an open collector transistor output Stray capacity on the wiring between the pulse generator and the inverter may disable transmission of the pulse train As a countermeasure against this problem insert a pull up resistor between the open collector output signal terminal X7 and the power source terminal terminal PLC if the switch selects the SINK mode input insert a pull down resistor between the output signal and the digital common terminal terminal CM if the switch selects the SOURCE mode input A recommended pull up down resistor is IKQ 2 W Check if the pulse train is correctly transmitted because stray capacity is significantly affected by the wire types and wiring conditions Fo tEn Fuji Electric 13916183699 021 60510862 Analog output pulse output transistor output and relay output terminals Symbol Name Functions Analog monitor The monitor signal for analog DC voltage 0 to 10 V or analog FMA function DC current 4 to 20 mA is output You can select the output form VO IO by switching the sli
69. ve and Active OFF Terminals Y5A and Y5C are opened non excited if the signal is active while they are normally closed Relay output 30A B C Alarm relay 1 Outputs a contact signal SPDT when a protective function output has been activated to stop the motor for any error Contact rating 250 VAC 0 3A cos b 0 3 48 VDC 0 5A 2 Any one of output signals assigned to terminals Y1 to Y4 can also be assigned to this relay contact to use it for signal output 3 Switching of the normal negative logic output is applicable to the following two contact output modes Active ON Terminals 30A and 30C are closed excited if the signal is active and Active OFF Terminals 30A and 30C are opened non excited if the signal is active while they are normally closed Relay output FO zten Fuji Electric 13916183699 021 60510862 2 18 2 3 Terminal Specifications RS 485 communications port Connector Name Functions RS 485 A communications port transmits data through the RS 485 communications multipoint protocol between the inverter and a personal computer port 2 or other equipment such as a PLC Terminals For setting of the terminating resistor refer to Setting up the on control PCB glide switches on page 2 20 I E n N amp D 2 gt 3 N RJ 45 RS 485 1 Used to connect the inverter with the keypad The inverter connector communications supplies the p
70. with DC power feed the power 24 VDC allowable range 22 to 27 VDC 100 mA max through the PLC terminal Short circuit between the terminals CMY and CM in this case CMY Transistor Common terminal for transistor output signals output common This terminal is electrically isolated from terminals CM s and 11 s Related Symbol Name Functions function codes Classifi cation E 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 In example a the input circuit of the PLC serves as a SINK for the control circuit output whereas in example b it serves as a SOURCE for the output lt Control circuit gt Programmable lt Control circuit gt ee logic controller ogic controller Photocoupler Current Photocoupler Current Transistor output a PLC serving as SINK b PLC serving as SOURCE Figure 2 8 Connecting PLC to Control Circuit YSA C General 1 A general purpose relay contact output usable as well as the purpose relay function of the transistor output terminal Y1 Y2 Y3 or output Y4 Contact rating 250 VAC 0 3 A cos 0 0 3 148 VDC 0 5 A 2 Switching of the normal negative logic output is applicable to the following two contact output modes Active ON Terminals Y5A and Y5C are closed excited if the signal is acti

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