High Performance, Vector Control Inverter User''''s Manual MEHT286 Copyright © 2012 Fuji Electric Co , Ltd All rights reserved No part of this publication may be reproduced or copied without prior writte[.]
High Performance, Vector Control Inverter User's Manual MEHT286 Copyright © 2012 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 Preface This manual provides all the information on the FRENIC-VG 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-VG Read them in conjunction with this manual as necessary Name Catalog Instruction Manual Material No Description MEH659 Product scope, features, specifications, external drawings, and options of the product INR-SI47-1580-E Acceptance inspection, mounting & wiring of the inverter, operation using the keypad, running the motor for a test, troubleshooting, and maintenance and inspection 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-VG 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, select 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 i How this manual is organized This manual contains Chapters through 13 and Appendices Chapter OVERVIEW This chapter describes the overview, features and the control system of the FRENIC-VG series and the recommended configuration for the inverter and peripheral equipment Chapter SPECIFICATIONS This chapter describes specifications of the output ratings, control system, dedicated motor specifications, and terminal functions for the FRENIC-VG series of inverters It also provides descriptions of the external dimensions, examples of basic connection diagrams, and details of the protective functions Chapter PREPARATION AND TEST RUN This chapter describes the operating and storage environments, installation and wiring, typical connection diagram, names and functions of keypad components, keypad operation, and test run procedure Chapter CONTROL AND OPERATION This chapter provides the main block diagrams for the control logic of the FRENIC-VG series of inverters It also contains overview tables of function codes and details of function codes Chapter USING STANDARD RS-485 This chapter describes the use of standard RS-485 communications ports and provides an overview of the FRENIC-VG Loader Chapter CONTROL OPTIONS This chapter describes the FRENIC-VG's control options Chapter APPLICATION EXAMPLES This chapter gives application examples of the FRENIC-VG series of inverters Chapter SELECTING PERIPHERAL EQUIPMENT This chapter describes how to use a range of peripheral equipment and options, FRENIC-VG's configuration with them, and requirements and precautions for selecting wires and crimp terminals Chapter 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 and inverter mode (HD, MD, or LD) Chapter 10 ABOUT MOTORS This chapter details vector motors that can be connected to the FRENIC-VG series of inverters Chapter 11 OPERATION DATA This chapter provides the characteristics data of the FRENIC-VG series of inverters running ii Chapter 12 REPLACEMENT DATA When replacing the former inverters (VG, VG3, VG5) with FRENIC-VG, refer to this section Chapter 13 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 Appendices iii CONTENTS Chapter OVERVIEW 1.1 Overview 1-1 1.1.1 Industry-best control performance 1-1 1.1.2 System support 1-1 1.1.3 Extensive built-in functionality 1-1 1.1.4 Broad capacity and application ranges 1-1 1.1.5 Global support 1-2 1.2 Features 1-3 1.2.1 Best-in-industry control performance 1-3 1.2.2 Support for various control methods (multi-drive function) 1-4 1.2.3 Broad capacity range/flexible application range 1-4 1.2.4 User program functionality (option: UPAC)*1 1-4 1.2.5 Extensive network support 1-5 1.2.6 Available inverter support loader 1-5 1.2.7 Extensive built-in functionality 1-6 1.2.8 Extensive maintenance and protective functionality 1-7 1.2.9 Environmental considerations 1-8 1.2.10 Simple, interactive keypad 1-10 1.2.11 Compliance with overseas standards 1-11 1.2.12 Compliance with functional safety standards 1-11 1.2.13 Compatibility with legacy models 1-11 1.3 Control Methods 1-12 1.3.1 Control method features and applications 1-12 1.3.1.1 Open-loop speed control 1-12 1.3.1.2 Closed-loop speed control 1-14 Chapter SPECIFICATIONS 2.1 Standard Model (Basic Type) 2-1 2.1.1 HD (High Duty)-mode inverters for heavy load 2-1 2.1.2 MD (Medium Duty)-mode inverters for medium load 2-3 2.1.3 LD (Low Duty)-mode inverters for light load 2-4 2.1.4 Rated current derating 2-6 2.2 Common Specifications 2-10 2.3 External Dimensions 2-16 2.3.1 Standard models 2-16 2.3.2 Keypad 2-27 2.4 Dedicated Motor Specifications 2-28 2.4.1 Induction motor (IM) with speed sensor 2-28 2.4.2 Permanent magnet synchronous motor (PMSM) with speed sensor 2-32 2.5 Protective Functions 2-38 2.6 Connection Diagrams and Terminal Functions 2-42 2.6.1 Connection diagrams 2-42 2.6.1.1 Running the MVK type of an induction motor (dedicated motor) 2-42 2.6.1.2 Running the GNF2 type of a permanent magnet synchronous motor (dedicated motor) 2-44 2.6.2 List of terminal functions 2-46 Chapter PREPARATION AND TEST RUN 3.1 Before Use 3-1 3.1.1 Acceptance inspection (Nameplates and type of inverter) 3-1 3.1.2 External view and terminal blocks 3-3 3.2 Precautions for Using Inverters 3-5 3.2.1 Installation environment 3-5 3.2.2 Storage environment 3-6 iv 3.2.3 Wiring precautions 3-7 3.2.4 Precautions for connection of peripheral equipment 3-8 3.2.5 Noise reduction 3-12 3.2.6 Leakage current 3-12 3.2.7 Precautions in driving a permanent magnet synchronous motor (PMSM) 3-12 3.3 Mounting and Wiring the Inverter 3-13 3.3.1 Operating environment 3-13 3.3.2 Installing the Inverter 3-14 3.3.3 Wiring 3-16 3.3.3.1 Removing and mounting the front cover and the wiring guide 3-16 3.3.3.2 Screw specifications and recommended wire sizes 3-17 3.3.3.3 Arrangement of terminals 3-19 3.3.3.4 Wiring precautions 3-22 3.3.3.5 Connection diagram 3-25 3.3.3.6 Detailed functions of main circuit terminals and grounding terminals 3-27 3.3.3.7 Switching connectors 3-31 3.3.3.8 Detailed functions of control circuit terminals 3-34 3.3.3.9 Setting up the slide switches 3-42 3.3.4 Mounting and connecting a keypad 3-44 3.3.4.1 Parts required for connection 3-44 3.3.4.2 Mounting procedure 3-44 3.3.5 USB connectivity 3-48 3.4 Operation Using the Keypad 3-49 3.4.1 Names and functions of keypad components 3-49 3.4.2 Overview of operation modes 3-52 3.4.3 Running mode 3-53 3.4.3.1 Configuring the speed command 3-53 3.4.3.2 Running or stopping the motor 3-54 3.4.3.3 Monitoring the running status on the LED monitor 3-56 3.4.3.4 Jogging (inching) the motor 3-57 3.4.3.5 Monitoring light alarms 3-58 3.4.4 Programming mode 3-60 3.4.4.1 Selecting language Menu #0 "LANGUAGE" 3-66 3.4.4.2 Configuring function codes Menu #1 "DATA SET" 3-67 3.4.4.3 Checking function code data Menu #2 "DATA CHECK" 3-69 3.4.4.4 Monitoring the running status Menu #3 "OPR MNTR" 3-71 3.4.4.5 Checking I/O signal status Menu #4 "I/O CHECK" 3-74 3.4.4.6 Reading maintenance information Menu #5 "MAINTENANCE" 3-77 3.4.4.7 Measuring load factor Menu #6 "LOAD FCTR" 3-79 3.4.4.8 Reading alarm information Menu #7 "ALM INF" 3-80 3.4.4.9 Viewing causes of alarm Menu #8 "ALM CAUSE" 3-83 3.4.4.10 Copying data Menu #10 "DATA COPY" 3-84 3.4.4.11 Checking changed function codes Menu #11 "CHANGES" 3-86 3.4.4.12 Setting the calendar clock Menu #12 "DATE/TIME" 3-87 3.4.4.13 Limiting function codes to be displayed Menu #14 "LIMITED FC" 3-90 3.5 Test Run Procedure 3-91 3.5.1 Checking prior to powering On 3-92 3.5.2 Powering ON and checking 3-93 3.5.2.1 Checking the input state of PG (pulse generator) signals 3-93 3.5.2.2 Mounting direction of a PG (pulse generator) and PG signals 3-94 3.5.3 Selecting a desired motor drive control 3-95 3.5.3.1 Vector control for IM with speed sensor 3-95 3.5.3.2 Vector control for IM without speed sensor 3-97 3.5.3.3 Vector control for PMSM with speed sensor and magnetic pole position sensor 3-99 3.5.3.4 V/f control for IM 3-101 3.5.4 Running the inverter for operation check 3-103 3.5.4.1 Test run procedure for induction motor (IM) 3-103 3.5.4.2 Test run procedure for permanent magnet synchronous motor (PMSM) 3-104 v 3.5.5 Selecting a speed command source 3-106 3.5.5.1 Setting up a speed command from the keypad 3-106 3.5.5.2 Setting up a speed command with an external potentiometer 3-106 3.5.5.3 Setting up a speed command with multistep speed selection 3-107 3.5.6 Selecting a run command source 3-108 3.5.6.1 Setting up a run command from the keypad 3-108 3.5.6.2 Setting up a run command with digital input signals (terminals [FWD] and [REV]) 3-108 Chapter CONTROL AND OPERATION 4.1 Block Diagrams for Control Logic 4-1 4.1.1 Operation Command 4-1 4.1.2 Speed Command Selection Section 4-2 4.1.3 Acceleration/deceleration Calculation, Speed Limiting, and Position Control Input Section 4-3 4.1.4 Motor Speed/Line Speed Detection 4-4 4.1.5 Pulse Train Command Input Section and Position Detection Section 4-5 4.1.6 Speed Control and Torque Command Section 4-6 4.1.7 Torque Limit, Torque Current Command, and Magnetic-flux Command Section 4-7 4.1.8 Current Control and Vector Control Section 4-8 4.1.9 PID Calculation Section 4-9 4.1.10 Load Adaptive Control Section 4-10 4.1.11 Motor Temperature Detection Section 4-11 4.1.12 Function Selection Digital Input 4-12 4.1.13 Function Selection Digital Output/Fault Output 4-13 4.1.14 Function Selection Analog Input/Output 4-14 4.1.15 Link Command Function Selection 4-15 4.1.16 Enabling to Write to/Recording Function Codes 4-16 4.2 Function Code Tables 4-17 4.2.1 Function Code Groups and Function Codes 4-17 4.2.2 About the Contents of Column Headers in Function Code Tables 4-18 4.2.3 Function Code Tables 4-19 4.2.4 Data Format List 4-61 4.2.4.1 Data Type to 13 4-61 4.2.4.2 Data Type 12 to 145 4-61 4.3 Details of Function Codes 4-78 4.3.1 F codes (Fundamental Functions) 4-78 4.3.2 E codes (Extension Terminal Functions) 4-120 4.3.3 C codes (Control Functions) 4-193 4.3.4 P codes (Motor Parameter Functions) 4-199 4.3.5 H codes (High Performance Functions) 4-214 4.3.6 A codes (Alternative Motor Functions) 4-266 4.3.7 o codes (Option Functions) 4-269 4.3.8 L codes (Lift Functions) 4-277 Chapter USING STANDARD RS-485 5.1 Standard RS-485 Communications Ports 5-1 5.1.1 RS-485 common specifications 5-2 5.1.2 Terminal specifications for RS-485 communications 5-3 5.1.3 Connection method 5-4 5.1.4 Communications support devices 5-6 5.1.4.1 Converters 5-6 5.1.4.2 Cables 5-7 5.1.5 Link functions 5-7 5.1.5.1 Link command permission selection 5-7 5.1.5.2 Link edit permission selection 5-8 5.1.5.3 S range option priority 5-8 5.1.6 Referencing and changing data 5-9 5.1.6.1 Write restrictions for function codes 5-9 vi 5.1.6.2 Negative response and error response 5-10 5.1.6.3 No response 5-10 5.1.7 RS-485 function codes 5-11 5.1.7.1 Response interval time (H39) 5-11 5.1.7.2 Disconnection detection time (H38) 5-12 5.1.7.3 Character timeouts 5-12 5.1.7.4 Timeouts on the master side 5-12 5.1.8 Host side procedures 5-13 5.1.8.1 Read procedure 5-13 5.1.8.2 Write procedure 5-14 5.1.9 RAS 5-15 5.1.9.1 Communication errors 5-15 5.1.10 Communication error measures 5-18 5.2 Fuji General-purpose Communications 5-19 5.2.1 Message format 5-19 5.2.2 Transmission frame 5-19 5.2.3 Standard frame 5-20 5.2.4 Option frame 5-23 5.2.5 Negative response frame 5-27 5.2.6 Field descriptions 5-28 5.2.6.1 Data field 5-28 5.2.6.2 Sum-check field 5-29 5.2.7 Communication examples 5-29 5.2.7.1 Standard frame 5-29 5.2.7.2 Option frame 5-30 5.2.7.3 ASCII code table 5-31 5.2.7.4 Program example 5-32 5.3 Modbus RTU 5-33 5.3.1 Message format 5-33 5.3.2 Transmission frame 5-34 5.3.2.1 Reading function codes 5-35 5.3.2.2 Writing single function codes 5-36 5.3.2.3 Writing multiple function codes 5-37 5.3.2.4 Maintenance code 5-38 5.3.2.5 Error response 5-39 5.3.3 Error checking 5-40 5.3.3.1 CRC-16 5-40 5.3.3.2 CRC-16 algorithm 5-41 5.3.3.3 CRC-16 calculation example 5-42 5.3.3.4 Calculating frame length 5-43 5.3.4 Communication examples 5-44 5.3.4.1 Reading 5-44 5.4 FRENIC-VG Loader Overview 5-45 5.4.1 Specifications 5-45 5.5 Connection 5-46 5.5.1 USB connection 5-46 5.5.1.1 RS-485 connection 5-46 5.5.2 Function overview 5-47 5.5.2.1 Setting function codes 5-47 5.5.2.2 Trace back 5-47 Chapter CONTROL OPTIONS 6.1 Common Specifications 6-1 6.1.1 Specifications table 6-1 6.1.2 Inspecting options after delivery 6-3 6.1.2.1 Inspecting options 6-3 6.1.2.2 Operating environment 6-4 vii 6.1.3 Storing options 6-5 6.1.3.1 Temporary storage 6-5 6.1.3.2 Long-term storage 6-5 6.1.4 Installing internal options (OPC-VG1-□□) 6-6 6.1.4.1 Removing the front cover 6-6 6.1.4.2 Installing a digital 8-bit communications option card 6-7 6.1.4.3 Installing a digital 8-bit option card 6-9 6.1.4.4 Installing a digital 16-bit option card 6-11 6.2 PG Interface Expansion Card 6-12 6.2.1 Product overview 6-12 6.2.2 Model and specifications 6-13 6.2.2.1 Model 6-13 6.2.2.2 Specifications 6-14 6.2.3 External dimension diagram 6-18 6.2.4 Basic connection diagram 6-19 6.2.4.1 Terminal connections 6-19 6.2.4.2 Wiring 6-20 6.2.4.3 Speed control 6-21 6.2.4.4 Line speed control 6-22 6.2.4.5 Pulse train operation and synchronized operation 6-23 6.2.5 Synchronized operation 6-25 6.2.5.1 Synchronized operation system architecture 6-25 6.2.5.2 Synchronized operation method 6-27 6.2.5.3 Function codes 6-29 6.2.6 Check functions 6-34 6.2.6.1 Optional equipment check 6-34 6.2.6.2 I/O check 6-34 6.2.7 Protective functionality 6-34 6.3 Synchronous Motor Drive PG Interface Card 6-35 6.3.1 Product overview 6-35 6.3.2 Model and specifications 6-36 6.3.2.1 Model 6-36 6.3.2.2 Specifications 6-37 6.3.2.3 Using the card in combination with a Fuji motor 6-38 6.3.3 External dimension diagram 6-39 6.3.4 Basic connection diagram 6-40 6.3.4.1 Line driver type 6-41 6.3.4.2 Open collector output type 6-42 6.3.4.3 Connection Diagram for Fuji servos 6-43 6.3.5 Function codes 6-44 6.3.5.1 Synchronous motor drive PG interface card function codes 6-44 6.3.5.2 Motor parameters 6-44 6.3.6 Check functions 6-45 6.3.6.1 Optional equipment check 6-45 6.3.7 Protective functionality 6-45 6.4 T-Link Interface Card 6-46 6.4.1 Product overview 6-46 6.4.2 Model and specifications 6-47 6.4.2.1 Inverter type 6-47 6.4.2.2 Specifications 6-47 6.4.3 External dimensions 6-49 6.4.3.1 Terminal function 6-49 6.4.4 Basic connection diagram 6-50 6.4.5 Function code 6-52 6.4.6 Protective operation 6-54 6.4.6.1 Light and heavy alarms 6-54 6.4.6.2 Protective operation function code 6-55 6.4.7 Data allocation addresses 6-57 viii ... the inverter may operate with acceleration/deceleration or speed different from the commanded ones Design the machine so that safety is ensured even in such cases key on the keypad is effective... 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 within the recommended... chapter describes the FRENIC- VG'' s control options Chapter APPLICATION EXAMPLES This chapter gives application examples of the FRENIC- VG series of inverters Chapter SELECTING PERIPHERAL EQUIPMENT