High Performance Inverter FRENIC-Ace Instruction Manual Thank you for purchasing our multifunction FRENIC-Ace series of inverters. • Be sure to set the destination on inverter type FRN****E2S/E2E-2G�/4G�/7G� for the initial power supply. Without setting the destination, the inverter cannot be operated. For details, refer to 4.4 Destination setting. • This product is designed to drive a three-phase motor under variable speed control. Read through this instruction 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 manual prepared for that optional device. • This manual provides only major functions of the FRENIC-Ace series. For details, refer to the FRENIC-Ace User's Manual. 汉语版的这个文件可以从以下站点下载。 Chinese version of this document can be downloaded from the following site. https://www.fujielectric.com.cn/document/product_operation.html 本書の日本語版は下記サイトからダウンロードできます。 Japanese version of this document can be downloaded from the following site. http://www.fujielectric.co.jp/products/drive-download/ Fuji Electric Co., Ltd. INR-SI47-1733f-E Copyright © 2015 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 instruction 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. i Preface Thank you for purchasing our multifunction FRENIC-Ace series of inverters. This product is designed to drive a three-phase induction motor or a three-phase permanent magnet synchronous motor under variable speed control. This manual provides all the information on the FRENIC-Ace (Global model) 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 if necessary. Name Material No. Description Catalog 24A1-E-0042 Product scope, features, specifications, external drawings, and options of the product FRENIC-Ace User's Manual 24A7-E-0043 Product details control block diagrams, specifications, and external dimensions RS-485 Communication User's Manual 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 User’s Manual for China model. 24A7-C-0043 This manual is written in simplified Chinese. User’s Manual for Japanese model. 24A7-J-0088 This manual is written in Japanese. *Available soon The materials are subject to change without notice. Be sure to obtain the latest editions for use. ii CONTENTS BEFORE USE Chapter 11.1 Acceptance Inspection (Nameplates and Inverter Type)··························································· 1-1 1.2 External View and Terminal Blocks ······················································································ 1-3 1.3 Precautions for Using Inverters ·························································································· 1-5 1.3.1 Usage environment ····································································································· 1-5 1.3.2 Storage environment ··································································································· 1-7 [ 1 ] Temporary storage ······································································································· 1-7 [ 2 ] Long-term storage ······································································································· 1-7 INSTALLATION AND WIRING Chapter 22.1 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/ terminal cover and wiring guide ··························· 2-6 2.2.3 Precautions for wiring ·································································································· 2-8 2.2.4 Precautions for long wiring (between inverter and motor) ···················································· 2-9 2.2.5 Main circuit terminals ·································································································· 2-11 [ 1 ] Screw specifications ···································································································· 2-11 [ 2 ] Terminal layout diagram (main circuit terminal) ································································· 2-14 [ 3 ] Recommended wire size (main circuit terminals) ······························································ 2-16 [ 4 ] Description of terminal functions (main circuit terminal) ······················································ 2-37 2.2.6 Control circuit terminals (common to all models) ······························································ 2-41 [ 1 ] Screw specifications and recommended wire size (control circuit terminals) ··························· 2-41 [ 2 ] Terminal layout diagram (control circuit terminal) ······························································ 2-41 [ 3 ] Description of terminal functions (control circuit terminal) ··················································· 2-42 2.2.7 Switching connector (types FRN0203E2■-4 or above) ·················································· 2-50 2.2.8 Operating slide switches ····························································································· 2-52 2.3 Attachment and Connection of Keypad ·············································································· 2-53 2.3.1 Parts required for connection ······················································································· 2-53 2.3.2 Attachment procedure ································································································ 2-54 2.4 RJ-45 Cover ················································································································· 2-57 OPERATION USING THE KEYPAD Chapter 33.1 Names and Functions of Keypad Components ······································································ 3-1 3.2 Overview of Operation Modes ···························································································· 3-3 TEST RUN PROCEDURE Chapter 44.1 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 Destination setting ··········································································································· 4-4 4.5 Switching the Applicable Motor Rating (ND, HD, HND and HHD Modes) ····································· 4-6 FUNCTION CODES Chapter 55.1 Function Codes Overview ································································································· 5-1 5.2 Function Codes Table ······································································································ 5-1 5.2.1 Supplementary note ···································································································· 5-1 5.2.2 Function codes table ··································································································· 5-3 5.2.3 Factory default value per applicable electric motor capacitance ·········································· 5-35 TROUBLESHOOTING Chapter 66.1 Protective Function ·········································································································· 6-1 iii 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 MAINTENANCE AND INSPECTION Chapter 77.1 Inspection Interval ··········································································································· 7-1 7.2 Daily Inspection··············································································································· 7-2 7.3 Periodic Inspection ·········································································································· 7-3 7.3.1 Periodic inspection 1--Before the inverter is powered ON or after it stops running····················· 7-3 7.3.2 Periodic inspection 2--When the inverter is ON or it is running ·············································· 7-4 7.4 List of Periodic Replacement Parts ······················································································ 7-4 7.4.1 Judgment on service life ······························································································· 7-5 [ 1 ] Measuring the capacitance of DC link bus capacitor in comparison with initial one at shipment 7-6 [ 2 ] Measuring the capacitance of the DC link bus capacitor under ordinary operating conditions ······· 7-7 [ 3 ] Early warning of lifetime alarm ························································································ 7-7 7.5 Measurement of Electrical Amounts in Main Circuit ································································· 7-8 7.6 Insulation Test ················································································································· 7-9 7.7 Inquiries about Product and Guarantee ················································································ 7-9 7.7.1 When making an inquiry ······························································································· 7-9 7.7.2 Product warranty ······································································································ 7-10 [ 1 ] Free of charge warranty period and warranty range ·························································· 7-10 [ 2 ] Exclusion of liability for loss of opportunity, etc. ································································· 7-11 [ 3 ] Repair period after production stop, spare parts supply period (holding period) ························ 7-11 [ 4 ] Transfer rights ············································································································ 7-11 [ 5 ] Service contents ········································································································· 7-11 [ 6 ] Applicable scope of service ··························································································· 7-11 APPENDICESAppendix G Conformity with Standards ························································································· 1 G.1 Compliance with European Standards () ······································································· 1 [ 1 ] Compliance with EMC standards ······················································································· 1 [ 2 ] Compliance with the low voltage directive in the EU ······························································· 6 G.2 Harmonic Component Regulation in the EU ······································································· 13 [ 1 ] General comments ········································································································ 13 [ 2 ] Compliance with the harmonic component regulation ··························································· 13 G.3 Compliance with UL Standards and Canadian Standards (cUL certification) ( ) ·············· 14 G.4 Compliance with the Radio Waves Act (South Korea) ( ) ··················································· 20 iv ■ Safety precautions Read this manual thoroughly before proceeding with installation, connections (wiring), operation, or maintenance and inspection. Ensure you have sound knowledge of the device 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. 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 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. Application • The FRENIC-Ace is designed to drive a three-phase induction motor. Do not use it for single-phase motors or for other purposes. Fire or an accident could occur. • The FRENIC-Ace may not be used for a life-support system or other purposes directly related to the human safety. • Though the FRENIC-Ace is manufactured under strict quality control, install safety devices for applications where serious accidents or property damages are foreseen in relation to the failure of it. An accident could occur. Installation • Install the inverter on a base made of metal or other non-flammable material. Otherwise, a fire could occur. • Do not place flammable object nearby. Doing so could cause fire. • Inverters FRN0085E2■-4G or above, whose protective structure is IP00, involve a possibility that a human body may touch the live conductors of the main circuit terminal block. Inverters to which an optional DC reactor is connected also involve the same. Install such inverters in an inaccessible place. Otherwise, electric shock or injuries could occur. • Do not support the inverter by its front cover during transportation. Doing so could cause a drop of the inverter and injuries. • Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the inverter or from accumulating on the heat sink. • When changing the positions of the top and bottom mounting bases for external cooling, use only the specified screws. Otherwise, a fire or an accident might result. • Do not install or operate an inverter that is damaged or lacking parts. Doing so could cause fire, an accident or injuries. v Wiring • If no zero-phase current (earth leakage current) detective device such as a ground-fault relay is installed in the upstream power supply line, in order to avoid the entire power supply system's shutdown undesirable to factory operation, install a residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) individually to inverters to break the individual inverter power supply lines only. Otherwise, a fire could occur. • When wiring the inverter to the power source, insert a recommended molded case circuit breaker (MCCB) or residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection) in the path of each pair of power lines to inverters. Use the recommended devices within the recommended current capacity. • Use wires in the specified size. • Tighten terminals with specified torque. Otherwise, a fire could occur. • When there is more than one combination of an inverter and motor, do not use a multicore cable for the purpose of handling their wirings together. • Do not connect a surge killer to the inverter's output (secondary) circuit. Doing so could cause a fire. • Be sure to connect an optional DC reactor (DCR) when the capacity of the power supply transformer exceeds 500 kVA and is 10 times or more the inverter rated capacity. Otherwise, a fire could occur. • Ground the inverter in compliance with the national or local electric code. • Be sure to ground the inverter's grounding terminals G. Otherwise, an electric shock or a fire could occur. • Qualified electricians should carry out wiring. • Be sure to perform wiring after turning the power OFF. Otherwise, an electric shock could occur. • Be sure to perform wiring after installing the inverter unit. Otherwise, an electric shock or injuries could occur. • Ensure that the number of input phases and the rated voltage of the product match the number of phases and the voltage of the AC power supply to which the product is to be connected. Otherwise, a fire or an accident could occur. • Do not connect the power supply wires to output terminals (U, V, and W). • When connecting a DC braking resistor (DBR), never connect it to terminals other than terminals P(+) and DB. Doing so could cause fire or an accident. • In general, sheaths of the control signal wires are not specifically designed to withstand a high voltage (i.e., reinforced insulation is not applied). Therefore, if a control signal wire comes into direct contact with a live conductor of the main circuit, the insulation of the sheath might break down, which would expose the signal wire to a high voltage of the main circuit. Make sure that the control signal wires will not come into contact with live conductors of the main circuit. Doing so could cause an accident or an electric shock. • Before changing the switches or touching the control circuit terminal symbol plate, turn OFF the power and wait at least five minutes for inverters FRN0115E2■-2 / FRN0072E2■-4 / FRN0011E2■-7 or below, or at least ten minutes for inverters FRN0085E2■-4 or above. Make sure that the LED monitor and charging lamp are turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped to the safe level (+25 VDC or below). Otherwise, an electric shock could occur. • The inverter, motor and wiring generate electric noise. Be careful about malfunction of the nearby sensors and devices. To prevent them from malfunctioning, implement noise control measures. Otherwise an accident could occur. vi Operation • Be sure to mount the front cover before turning the power ON. Do not remove the cover when the inverter power is ON. Otherwise, an electric shock could occur. • Do not operate switches with wet hands. Doing so could cause electric shock. • If the auto-reset function has been selected, the inverter may automatically restart and drive the motor depending on the cause of tripping. Design the machinery or equipment so that human safety is ensured at the time of restarting. Otherwise, an accident could occur. • If the stall prevention function (current limiter), automatic deceleration (anti-regenerative control), or 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 even in such cases. • The key on the keypad is effective only when the keypad operation is enabled with function code F02 (= 0, 2 or 3). When the keypad operation is disabled, prepare an emergency stop switch separately for safe operations. Switching the run command source from keypad (local) to external equipment (remote) by turning ON the "Enable communications link" command LE disables the key. To enable the key for an emergency stop, select the STOP key priority with function code H96 (= 1 or 3). • If any of the protective functions have been activated, first remove the cause. Then, after checking that the all run commands are set to OFF, release the alarm. If the alarm is released while any run commands are set to ON, the inverter may supply the power to the motor, running the motor. Otherwise, an accident could occur. • If you enable the "Restart mode after momentary power failure" (Function code F14 = 3 to 5), then the inverter automatically restarts running the motor when the power is recovered. Design the machinery or equipment so that human safety is ensured after restarting. • If the user configures the function codes wrongly without completely understanding the User's Manual, the motor may rotate with a torque or at a speed not permitted for the machine. • Starting auto-tuning involves motor rotation. Sufficiently check that motor rotation brings no danger beforehand. An accident or injuries could occur. • Even if the inverter has interrupted power to the motor, if the voltage is applied to the main circuit input terminals L1/R, L2/S, L3/T, L1/L and L2/N, voltage may be output to inverter output terminals U, V, and W. • Even if the motor is stopped due to DC braking or preliminary excitation, voltage is output to inverter output terminals U, V, and W. An electric shock may occur. • The inverter can easily accept high-speed operation. When changing the speed setting, carefully check the specifications of motors or equipment beforehand. Otherwise, injuries could occur. vii • Do not touch the heat sink and braking resistor because they become very hot. Doing so could cause burns. • The DC brake function of the inverter does not provide any holding mechanism. Injuries could occur. • Ensure safety before modifying the function code settings. Run commands (e.g., "Run forward" FWD), stop commands (e.g., "Coast to a stop" BX), and frequency change commands can be assigned to digital input terminals. Depending upon the assignment states of those terminals, modifying the function code setting may cause a sudden motor start or an abrupt change in speed. • When the inverter is controlled with the digital input signals, switching run or frequency command sources with the related terminal commands (e.g., SS1, SS2, SS4, SS8, Hz2/Hz1, Hz/PID, IVS, and LE) may cause a sudden motor start or an abrupt change in speed. • Ensure safety before modifying customizable logic related function code settings (U codes and related function codes) or turning ON the "Cancel customizable logic" terminal command CLC. Depending upon the settings, such modification or cancellation of the customizable logic may change the operation sequence to cause a sudden motor start or an unexpected motor operation. An accident or injuries could occur. Maintenance and inspection, and parts replacement • Before proceeding to the maintenance/inspection jobs, turn OFF the power and wait at least five minutes for inverters FRN0115E2■-2 / FRN0072E2■-4 / FRN0011E2■-7 or below, or at least ten minutes for inverters FRN0085E2■-4 or above. Make sure that the LED monitor and charging lamp are turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped to the safe level (+25 VDC or below). Otherwise, an electric shock could occur. • Always carry out the daily and periodic inspections described in the instruction/user's manual. Use of the inverter for long periods of time without carrying out regular inspections could result in malfunction or damage, and an accident or fire could occur. • It is recommended that periodic inspections be carryout every one to two years, however, they should be carried out more frequently depending on the usage conditions. • It is recommended that parts for periodic replacement be replaced in accordance with the standard replacement frequency indicated in the user's manual. Use of the product for long periods of time without replacement could result in malfunction or damage, and an accident or fire could occur. • Contact outputs [30A/B/C] use relays, and may remain ON, OFF, or undetermined when their lifetime is reached. In the interests of safety, equip the inverter with an external protective function. Otherwise, an accident or fire could occur. • Maintenance, inspection, and parts replacement should be made only by qualified persons. • Take off the watch, rings and other metallic objects before starting work. • Use insulated tools. Otherwise, an electric shock or injuries could occur. • Never modify the inverter. Doing so could cause an electric shock or injuries. Next >