High Performance Inverter User''''s Manual Thank you for purchasing our multifunction FRENIC Ace series of inverters • This product is designed to drive a three phase motor under variable speed control R[.]
High Performance Inverter User's Manual Thank you for purchasing our multifunction FRENIC-Ace series of inverters • This product is designed to drive a three-phase motor under variable speed control Read through this user's manual and become familiar with the handling procedure for correct use • Improper handling might result in incorrect operation, a short life, or even a failure of this product as well as the motor • Deliver this manual to the end user of this product Keep this manual in a safe place until this product is discarded • For how to use an optional device, refer to the instruction and installation manuals for that optional device 24A7-E-0043 Copyright © 2013 Fuji Electric Co., Ltd All rights reserved No part of this publication may be reproduced or copied without prior written permission from Fuji Electric 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 The purpose of this user's manual is to provide accurate information in handling, setting up and operating of the FRENIC-Ace series of inverters Please feel free to send your comments regarding any errors or omissions you may have found, or any suggestions you may have for generally improving the manual In no event will Fuji Electric Co., Ltd be liable for any direct or indirect damages resulting from the application of the information in this manual Preface Thank you for purchasing our multifunction FRENIC-Ace series of inverters This product is designed to drive a three-phase induction motor under variable speed control This manual provides all the information on the FRENIC-Ace series of inverters including its operating procedure and selection of peripheral equipment Before use, carefully read this manual for proper use Improper handling might result in incorrect operation, a short life, or even a failure of this product as well as the motor The table below lists the other materials related to the use of the FRENIC-Ace Read them in conjunction with this manual as necessary Name Catalog RS-485 Communication User's Manual Material No Description 24A1-E-0042 Product scope, features, specifications, external drawings, and options of the product 24A7-E-0021* Overview of functions implemented by using FRENIC-Ace RS-485 communications facility, its communications specifications, Modbus RTU/Fuji general-purpose inverter protocol, function codes and related data formats *Available soon The materials are subject to change without notice Be sure to obtain the latest editions for use i How this manual is organized This manual contains Chapters through 13 and Appendices Chapter BEFORE USE This chapter gives the check items to be used before the use of the inverter Chapter MOUNTING AND WIRING THE INVERTER This chapter describes the important points in installing and wiring inverters Chapter OPERATION USING THE KEYPAD This chapter describes keypad operation of the inverter Chapter TEST RUN PROCEDURE This chapter describes basic settings required for making a test run Chapter FUNCTION CODES This chapter explains the table of function code used in FRENIC-Ace, index per purpose, and the detail of each function code Chapter TROUBLESHOOTING This chapter describes troubleshooting procedures to be followed when the inverter malfunctions or detects an alarm or a light alarm condition In this chapter, first check whether any alarm code or the "light alarm" indication (l-al) is displayed or not, and then proceed to the troubleshooting items Chapter MAINTENANCE AND INSPECTION This chapter describes the maintenance and inspection items of the inverter Chapter BLOCK DIAGRAMS FOR CONTROL LOGIC This chapter describes the main block diagrams of the control section Chapter RUNNING THROUGH RS-485 COMMUNICATION This chapter describes an overview of inverter operation through the RS-485 and CANopen communications For details of RS-485 communication, refer to the RS-485 Communication User's Manual (24A7-E-0021) Chapter 10 SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES This chapter provides you with information about the inverter output torque characteristics, selection procedure, and equations for calculating capacities to help you select optimal motor and inverter models It also helps you select braking resistors, inverter mode (ND, HD, HND, or HHD), and motor drive control Chapter 11 SELECTING PERIPHERAL EQUIPMENT This chapter describes how to use a range of peripheral equipment and options, FRENIC-Ace's configuration with them, and requirements and precautions for selecting wires and crimp terminals Chapter 12 SPECIFICATIONS This chapter describes the output ratings, input power, basic functions and other specifications of the FRENIC-Ace standard model Chapter 13 EXTERNAL DIMENSIONS This chapter gives external dimensions of the inverter Appendices ii CONTENTS Chapter BEFORE USE ············································································································ 1-1 1.1 Acceptance Inspection (Nameplates and Inverter Type) ······························································· 1-1 1.2 External View and Terminal Blocks ·························································································· 1-3 1.3 Precautions for Using Inverters ······························································································· 1-4 1.3.1 Usage environment ········································································································ 1-4 1.3.2 Storage environment ······································································································ 1-6 1.3.3 Precautions for connection of peripheral equipment ······························································ 1-7 1.3.4 Noise reduction ············································································································· 1-9 1.3.5 Leakage current ············································································································ 1-9 1.3.6 Precautions in driving a permanent magnet synchronous motor (PMSM) ·································· 1-9 Chapter Installation and Wiring ································································································· 2-1 2.1 Installation ·························································································································· 2-1 2.2 Wiring ································································································································ 2-3 2.2.1 Basic Connection Diagram ······························································································ 2-3 2.2.2 Removal and Attachment of the Front Cover and Wiring Guide ··············································· 2-6 2.2.3 Precautions for Wiring ···································································································· 2-7 2.2.4 Precautions for Long Wiring (Between Inverter and Motor) ····················································· 2-9 2.2.5 Main Circuit Terminals ·································································································· 2-11 [ ] Screw Specifications and Recommended Wire Size (Main Circuit Terminals) 2-11 [ ] Terminal Layout Diagram (Main Circuit Terminal) 2-24 [ ] Description of Terminal Functions (Main Circuit Terminal) 2-24 2.2.6 Control Circuit Terminals (Common to All Models) ······························································ 2-29 [ ] Screw Specifications and Recommended Wire Size (Control Circuit Terminal) 2-29 [ ] Terminal Layout Diagram (Control Circuit Terminal) 2-29 [ ] Description of Terminal Functions (Control Circuit Terminal) 2-30 2.2.7 Switching Connector ···································································································· 2-37 2.2.8 Operating Various Switches ··························································································· 2-39 2.3 Attachment and Connection of Keypad ··················································································· 2-41 2.3.1 Parts Required for Connection ······················································································· 2-41 2.3.2 Attachment Procedure ·································································································· 2-41 2.4 RJ-45 Cover······················································································································ 2-45 Chapter OPERATION USING THE KEYPAD ··············································································· 3-1 3.1 Names and Functions of Keypad Components ··········································································· 3-1 3.2 Overview of Operation Modes ································································································· 3-3 3.3 Running Mode ····················································································································· 3-5 3.3.1 Monitoring the running status ··························································································· 3-5 3.3.2 Monitoring light alarms ···································································································· 3-7 3.3.3 Running or stopping the motor ························································································· 3-8 3.3.4 Setting up reference frequency from the keypad ·································································· 3-8 3.3.5 Setting up PID commands from the keypad ········································································· 3-9 [ ] Settings under PID process control 3-9 [ ] Settings under PID dancer control 3-11 3.3.6 Jogging Operation ······································································································· 3-13 3.3.7 Remote and local modes ······························································································· 3-14 3.4 Programming Mode ············································································································ 3-15 3.4.1 Setting up function codes "Data Setting:!f through!k " ············································ 3-16 3.4.2 Checking changed function codes "Data Checking: "rep " ··············································· 3-17 3.4.3 Monitoring the running status "Drive Monitoring: #ope " ···················································· 3-18 3.4.4 Checking I/O signal status "I/O Checking: $i_o "····························································· 3-22 iii 3.4.5 Reading maintenance information "Maintenance Information: %che " ··································· 3-26 3.4.6 Reading alarm information "Alarm Information: &al " ························································ 3-30 3.4.7 Setting up basic function codes quickly "Quick Setup: *fn:" ·············································· 3-33 3.5 Alarm Mode ······················································································································ 3-35 3.5.1 Releasing the alarm and switching to Running mode ·························································· 3-35 3.5.2 Displaying the alarm history ··························································································· 3-35 3.5.3 Displaying the status of inverter at the time of alarm ··························································· 3-35 3.5.4 Switching to Programming mode ···················································································· 3-36 Chapter TEST RUN PROCEDURE ···························································································· 4-1 4.1 Test Run Procedure Flowchart ································································································ 4-1 4.2 Checking Prior to Powering On ······························································································· 4-2 4.3 Powering ON and Checking ··································································································· 4-3 4.4 Switching the Applicable Motor Rank (ND, HD, HND and HHD Modes) ··········································· 4-3 4.5 Selecting a Desired Motor Drive Control···················································································· 4-4 4.5.1 V/f control with slip compensation inactive ·········································································· 4-4 4.5.2 Vector control without speed sensor (Dynamic torque vector) ················································· 4-4 4.5.3 V/f control with slip compensation active ············································································· 4-5 4.5.4 Performance comparison for drive controls (summary) ·························································· 4-5 4.5.5 Configuring function codes ······························································································ 4-6 [ ] Basic settings < > 4-6 [ ] Basic settings < > 4-7 4.5.6 Auto-tuning motor parameters ·························································································· 4-7 [ ] Turning procedure < > 4-7 4.6 Running the Inverter for Motor Operation Check ········································································· 4-9 4.6.1 Test run procedure ········································································································ 4-9 4.6.2 Check points during a test run ·························································································· 4-9 4.6.3 Modification of motor control function code data ··································································· 4-9 4.7 Selecting a Frequency Command Source················································································ 4-10 4.7.1 Setting up a frequency command from the keypad ····························································· 4-10 4.7.2 Setting up a frequency command with an external potentiometer ··········································· 4-10 4.7.3 Setting up a frequency command with multistep frequency selection ······································ 4-11 4.8 Selecting a Run Command Source ························································································ 4-12 4.8.1 Setting up a run command from the keypad ······································································ 4-12 4.8.2 Setting up a run command with digital input signals (terminals [FWD] and [REV]) ····················· 4-12 Chapter Function code ············································································································ 5-1 5.1 Function code overview ········································································································· 5-1 5.2 Function code table ·············································································································· 5-1 5.2.1 Supplementary note ······································································································· 5-1 5.2.2 Function code table ········································································································ 5-3 5.3 Description of function code ································································································· 5-29 5.3.1 F code (Basic function) ································································································· 5-29 [ ] Frequency setting by keypad (F01 = (Factory default state), 8) ············································ 5-31 [ ] Setting up a reference frequency using analog input (F01 = to 3, 5) ······································ 5-31 [ ] Frequency setting by digital input signal "UP"/"DOWN" (F01=7) ············································· 5-37 [ ] Frequency setting using pulse train input (F01 = 12) ···························································· 5-38 5.3.2 E codes (Extension terminal functions) ············································································· 5-76 5.3.3 C codes (Control functions) ·························································································· 5-107 5.3.4 P codes (Motor parameters) ······················································································· 5-115 5.3.5 H codes (High performance functions) ············································································ 5-120 [ ] Measuring the capacitance of DC link bus capacitor in comparison with initial one at shipment ···· 5-131 [ ] Measuring the capacitance of DC link bus capacitor under ordinary operating conditions at power shutdown ·················································································································· 5-132 iv 5.3.6 A codes (Motor parameters) ······················································································· 5-146 5.3.7 J Codes (Applied Functions) ························································································· 5-148 [ ] PID command with the [Image1] / [Image2] keys on the keypad (J02 = 0, factory default) ··········· 5-149 [ ] PID command by analog inputs (J02 = 1) ········································································· 5-149 [ ] PID command with UP/DOWN control (J02 = 3) ································································ 5-152 [ ] PID command via communications link (J02 = 4) ······························································· 5-152 5.3.8 d Codes (Applied Functions 2) ······················································································ 5-167 5.3.9 U Codes (Customizable logic operation) ·········································································· 5-168 5.3.10 U1 codes (Customizable logic operation) ········································································· 5-190 5.3.11 y codes (Link function) ································································································· 5-195 Chapter TROUBLESHOOTING ································································································· 6-1 6.1 Protective function ················································································································ 6-1 6.2 Before Proceeding with Troubleshooting ··················································································· 6-2 6.3 If an Alarm Code Appears on the LED Monitor ··········································································· 6-3 6.3.1 Alarm code list ·············································································································· 6-3 6.3.2 Causes, Checks and Measures of Alarms ··········································································· 6-6 [ ] cof PID feedback wire break 6-6 [ ] dba Braking transistor error 6-6 [ ] dbh Braking resistor overheated 6-6 [ ] ecf EN circuit failure 6-7 [ ] ecl Customized logic failure 6-7 [ ] ef Ground fault 6-7 [ ] er1 Memory error 6-7 [ ] er2 Keypad communications error 6-8 [ ] er3 CPU error 6-8 [ 10 ] er4 Option communications error 6-8 [ 11 ] er5 Option error (To be responded soon.) 6-8 [ 12 ] er6 Operation error 6-9 [ 13 ] er7 Tuning error 6-9 [ 14 ] er8 RS-485 communications error (Communications port 1)/ erp RS-485 communications error (Communications port 2) 6-10 [ 15 ] erd Step-out detection/detection failure of magnetic pole position at startup (To be responded soon.) 6-10 [ 16 ] ere Speed inconsistency / Excessive speed deviation (To be responded soon.) 6-11 [ 17 ] erf Data saving error during undervoltage 6-11 [ 18 ] ero Positioning control error (To be responded soon) 6-12 [ 19 ] err Simulated failure 6-12 [ 20 ] ert CAN communications failure 6-12 [ 21 ] fus DC fuse-blowing 6-12 [ 22 ] lin Input phase loss 6-13 [ 23 ] lu Undervoltage 6-13 [ 24 ] 0cn Instantaneous overcurrent 6-14 [ 25 ] 0h1 Cooling fin overheat 6-15 [ 26 ] 0h2 External alarm 6-15 [ 27 ] 0h3 Inverter internal overheat 6-15 [ 28 ] 0h4 Motor protection (PTC thermistor) 6-16 [ 29 ] 0ln Motor overloads to 6-16 [ 30 ] 0lu Inverter overload 6-17 [ 31 ] 0pl Output phase-failure detection 6-17 [ 32 ] 0s Overspeed protection 6-18 v [ 33 ] 0un Overvoltage 6-18 [ 34 ] pbf Charger circuit fault 6-19 [ 35 ] p9 PG wire break (To be responded soon.) 6-19 6.4 If the "Light Alarm" Indication (l-al) Appears on the LED Monitor ·············································· 6-20 6.5 When codes other than alarm codes and light alarm indication (l-al) are displayed ······················ 6-22 6.5.1 Abnormal motor operation ····························································································· 6-22 [ ] The motor does not rotate 6-22 [ ] The motor rotates, but the speed does not increase 6-24 [ ] The motor runs in the opposite direction to the command 6-25 [ ] Speed fluctuation or current oscillation (e.g., hunting) occurs during running at constant speed 6-25 [ ] Unpleasant noises are emitted from motor or noises fluctuate 6-26 [ ] Motor is not accelerated or decelerated according to set-up acceleration or deceleration time 6-26 [ ] The motor does not restart even after the power recovers from a momentary power failure 6-27 [ ] Motor generates heat abnormally 6-27 [ ] The motor does not run as expected 6-27 [ 10 ] Motor stalls during acceleration 6-28 6.5.2 Problems with inverter settings ······················································································· 6-29 [ ] Nothing appears on the LED monitor 6-29 [ ] The desired menu is not displayed 6-29 [ ] Display of under bars (_ _ _ _) 6-29 [ ] Display of center bars ( ) 6-30 ] Display of parenthesis 6-30 [5] c [ ] Data of function codes cannot be changed 6-30 [ ] Function code data are not changeable (change from link functions) 6-31 Chapter MAINTENANCE AND INSPECTION ··············································································· 7-1 7.1 Inspection Interval ················································································································ 7-1 7.2 Daily Inspection ··················································································································· 7-2 7.3 Periodic Inspection ··············································································································· 7-3 [ ] Periodic inspection Before the inverter is powered ON or after it stops running 7-3 [ ] Periodic inspection When the inverter is ON or it is running 7-4 7.4 List of Periodic Replacement Parts ·························································································· 7-5 7.4.1 Judgment on service life ································································································· 7-6 [ ] Measurement of discharging time of the DC link bus capacitor 7-6 [ ] ON-time counting of DC link bus capacitor 7-7 7.5 Measurement of Electrical Amounts in Main Circuit ····································································· 7-9 7.6 Insulation Test ··················································································································· 7-10 7.7 Inquiries about Product and Guarantee ··················································································· 7-11 7.7.1 When making an inquiry ································································································ 7-11 7.7.2 Product warranty ········································································································· 7-11 [ ] Free of charge warranty period and warranty range .7-11 [ ] Exclusion of liability for loss of opportunity, etc 7-12 [ ] Repair period after production stop, spare parts supply period (holding period) 7-12 [ ] Transfer rights 7-12 [ ] Service contents 7-12 [ ] Applicable scope of service 7-12 Chapter BLOCK DIAGRAMS FOR CONTROL LOGIC ··································································· 8-1 8.1 Meanings of symbols used in the control block diagrams ······························································ 8-1 8.2 Frequency setting section ······································································································ 8-2 8.3 Operation command section ··································································································· 8-5 8.4 PID Control Section (for Processing) ························································································ 8-6 8.5 PID Control Section (for Dancer) ····························································································· 8-7 8.6 Control Section ···················································································································· 8-8 8.6.1 8.7 V/f Control ···················································································································· 8-8 FM Output Section ············································································································· 8-10 vi Chapter 9.1 RUNNING THROUGH RS-485 COMMUNICATION ··························································· 9-1 Overview of RS-485 Communication ························································································ 9-1 9.1.1 RS-485 common modes ································································································· 9-2 9.1.2 Terminal mode ·············································································································· 9-3 [ ] RS-485 communication port (for connecting the keypad) mode 9-3 [ ] RS-485 communication port mode (only for FRN-E2S-4A, E) 9-3 [ ] RS-485 communication port (terminal block) mode (only for FRN-E2S-4C) 9-4 9.1.3 Connection method ········································································································ 9-5 9.1.4 RS-485 connection devices ····························································································· 9-8 [ ] Converter 9-8 [ ] Requirements for the cable (COM port 1: for RJ-45 connector) 9-9 [ ] Requirements for the cable (COM port 2: for RS-485 connector) 9-9 [ ] Branch adapter for multi-drop 9-9 9.1.5 9.2 RS-485 noise suppression ······························································································· 9-9 CANopen communication ···································································································· 9-10 9.2.1 Modes ······················································································································· 9-10 9.2.2 Connection method ······································································································ 9-11 [ ] Basic connection configuration .9-11 [ ] Terminal mode 9-12 9.2.3 Inverter function codes related to CANopen setting ····························································· 9-13 9.2.4 Procedures to establish CANopen communication ······························································ 9-14 9.2.5 PDO protocol ·············································································································· 9-15 [ ] About PDO protocol 9-15 [ ] Reception PDO (from master to inverter) 9-16 [ ] Transmission PDO (from inverter to master) 9-18 [ ] Communication parameters of reception PDO 9-19 [ ] Communication parameters of transmission PDO 9-20 9.2.6 SDO protocol ·············································································································· 9-22 [ ] About SDO 9-22 [ ] Response on SDO error 9-22 9.2.7 Other services ············································································································ 9-23 9.2.8 Object list ··················································································································· 9-24 [ ] Objects in the communication profile area 9-24 [ ] Objects in the profile area specific to Fuji Electric 9-27 9.2.9 Standard device profile area ·························································································· 9-29 9.2.10 Inverter operation in CANopen communication ·································································· 9-29 [ ] Operation according to CANopen's drive profile (DSP 402) 9-29 [ ] Operation according to the inverter function code S06 9-34 9.2.11 Heartbeat and Node Guarding ························································································ 9-38 [ ] Heartbeat 9-38 [ ] Node Guarding 9-39 9.2.12 Behavior upon detection of CANopen network disconnection ················································ 9-41 9.2.13 Alarm code list ············································································································ 9-42 9.2.14 Other points to note ····································································································· 9-43 9.2.15 Keypad LED operation monitor “3_40” ············································································· 9-43 9.3 FRENIC loader overview ····································································································· 9-43 9.3.1 Modes ······················································································································· 9-43 9.3.2 Connection ················································································································· 9-44 9.3.3 Function overview ········································································································ 9-44 [ ] Configuring inverter's function code 9-44 [ ] Multi-monitor 9-45 [ ] Running status monitor 9-46 [ ] Test-running 9-47 [ ] Real-time trace 9-48 [ ] Historical trace 9-49 vii Chapter 10 10.1 SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES ········································ 10-1 Motor Output Torque Characteristics ······················································································ 10-1 10.2 Selection Procedure ··········································································································· 10-3 10.3 Equations for selections······································································································· 10-6 10.3.1 Load torque during constant speed running ······································································· 10-6 [ ] General equation 10-6 [ ] Obtaining the required force F 10-6 10.3.2 Acceleration and deceleration time calculation ··································································· 10-8 [ ] Calculation of moment of inertia 10-8 [ ] Calculation of the acceleration time 10-10 [ ] Calculation of the deceleration time 10-11 [ ] Calculating non-linear acceleration/deceleration time 10-11 10.3.3 Heat energy calculation of braking resistor ······································································· 10-13 [ ] Calculation of regenerative energy 10-13 10.3.4 10.4 Calculating the RMS rating of the motor ·········································································· 10-14 Selecting an Inverter Drive Mode (ND/HD/HND/HHD) ······························································· 10-15 10.4.1 Precaution in making the selection ················································································· 10-15 10.4.2 Guideline for selecting inverter drive mode and capacity ····················································· 10-16 10.5 Selecting a Motor Drive Control ···························································································· 10-19 10.5.1 Features of motor drive controls ···················································································· 10-19 10.5.2 Selecting a Motor Drive Control by Purpose ····································································· 10-22 Chapter 11 SELECTING PERIPHERAL EQUIPMENT ····································································· 11-1 11.1 Configuring the FRENIC-Ace ································································································ 11-1 11.2 Currents Flowing across the Inverter Terminals ········································································ 11-2 11.3 Molded case circuit breaker (MCCB), residual-current-operated protective device (RCD)/ earth leakage circuit breaker (ELCB) and magnetic contactor (MC) ·············································· 11-4 11.3.1 Function overview ········································································································ 11-4 11.3.2 Connection example and criteria for selection of circuit breakers ··········································· 11-5 11.4 Surge killers for L-load ········································································································ 11-9 11.5 Arresters ························································································································· 11-10 11.6 Surge absorbers ··············································································································· 11-11 11.7 Filtering capacitors suppressing AM radio band noises ····························································· 11-12 11.8 Braking resistors (DBRs) and braking units ············································································· 11-13 11.8.1 Selecting a Braking Resistor ························································································· 11-13 [ ] Selection procedure 11-13 [ ] Notes on selection 11-13 11.8.2 Braking resistors (DBRs) ······························································································ 11-14 [ ] Standard model 11-14 [ ] 10%ED model .11-14 11.8.3 Braking units ············································································································· 11-15 11.8.4 Specifications ············································································································ 11-16 11.8.5 External dimensions ···································································································· 11-18 11.9 Power regenerative PWM converters, RHC series ··································································· 11-20 11.9.1 Overview ·················································································································· 11-20 11.9.2 Specifications ············································································································ 11-21 [ ] Standard specifications 11-21 [ ] Common specifications 11-21 11.9.3 Function specifications ································································································ 11-22 11.9.4 Converter configuration ································································································ 11-23 11.9.5 11.10 External dimensions ···································································································· 11-25 DC reactors (DCRs) ········································································································ 11-34 11.11 AC reactors (ACRs) ········································································································ 11-37 11.12 Surge suppression unit (SSU) ··························································································· 11-40 viii ... overload prevention control has been selected, the inverter may operate with acceleration/deceleration or frequency different from the commanded ones Design the machine so that safety is ensured... residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection) in the path of each pair of power lines to inverters Use the recommended devices... speed control This manual provides all the information on the FRENIC- Ace series of inverters including its operating procedure and selection of peripheral equipment Before use, carefully read