24A7 e 0043q

24A7 E 0043q 最終 High Performance Inverter FRENIC Ace Global model User’s Manual 24A7 E 0043g Thank you for purchasing our multifunction FRENIC Ace series of inverters • Be sure to set the destinatio[.]

High Performance Inverter

FRENIC-Ace

Global model User’s Manual

24A7-E-0043g

Thank you for purchasing our multifunction FRENIC-Ace series of inverters

• Be sure to set the destination on inverter type FRN****E2S/E2E-2/4/7 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 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

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 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

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

Catalog 24A1-E-0042 Product scope, features, specifications, external drawings, and options of the product

RS-485 Communication

User's Manual 24A1-E-0099

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

The materials are subject to change without notice Be sure to obtain the latest editions for use

This chapter describes the important points in installing and wiring inverters

Chapter 3 OPERATION USING THE KEYPAD

This chapter describes keypad operation of the inverter

Chapter 4 TEST RUN PROCEDURE

This chapter describes basic settings required for making a test run

Chapter 5 FUNCTION CODE

This chapter explains the table of function codes used in FRENIC-Ace, and the detail of each function code

Chapter 6 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 7 MAINTENANCE AND INSPECTION

This chapter describes the maintenance and inspection items of the inverter

Chapter 8 BLOCK DIAGRAMS FOR CONTROL LOGIC

This chapter describes the main block diagrams of the control section

Chapter 9 COMMUNICATION FUNCTIONS

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

(for suppressing harmonics) 1-8[ 4 ] PWM converter for correcting the inverter input power factor 1-8[ 5 ] Molded case circuit breaker (MCCB) / residual-current-operated protective device (RCD) / earth leakage circuit breaker (ELCB) 1-9[ 6 ] Magnetic contactor (MC) in the inverter input (primary) circuit 1-9[ 7 ] Magnetic contactor (MC) in the inverter output (secondary) circuit 1-9[ 8 ] Surge absorber/surge killer 1-91.3.4 Noise reduction 1-101.3.5 Leakage current 1-101.3.6 Precautions in driving a permanent magnet synchronous motor (PMSM) 1-10

INSTALLATION AND WIRING

Chapter 2

2.1 Installation 2-12.2 Wiring 2-32.2.1 Basic connection diagram 2-32.2.2 Removal and attachment of the front cover/ terminal cover and wiring guide 2-62.2.3 Precautions for wiring 2-82.2.4 Precautions for long wiring (between inverter and motor) 2-102.2.5 Main circuit terminals 2-12[ 1 ] Screw specifications 2-12[ 2 ] Terminal layout diagram (main circuit terminal) 2-15[ 3 ] Recommended wire size (main circuit terminals) 2-18[ 4 ] Description of terminal functions (main circuit terminal) 2-402.2.6 Control circuit terminals (common to all models) 2-44[ 1 ] Screw specifications and recommended wire size (control circuit terminals) 2-44[ 2 ] Terminal layout diagram (control circuit terminal) 2-44[ 3 ] Description of terminal functions (control circuit terminal) 2-452.2.7 Switching connector (types FRN0203E2■-4 or above) 2-532.2.8 Operating slide switches 2-552.3 Attachment and Connection of Keypad 2-572.3.1 Parts required for connection 2-572.3.2 Attachment procedure 2-572.4 RJ-45 Cover 2-61

OPERATION USING THE KEYPAD

Chapter 3

3.1 Names and Functions of Keypad Components 3-13.2 Overview of Operation Modes 3-33.3 Running Mode 3-53.3.1 Monitoring the running status 3-53.3.2 Monitoring light alarms 3-7

3.4.1 Setting up function codes “Data Setting:!f through!o ” 3-173.4.2 Checking changed function codes “Data Checking: "rep ” 3-183.4.3 Monitoring the running status “Drive Monitoring: #ope ” 3-193.4.4 Checking I/O signal status “I/O Checking: $i_o” 3-233.4.5 Reading maintenance information “Maintenance Information: %che ” 3-273.4.6 Reading alarm information “Alarm Information: &al” 3-313.4.7 Copying data “Data Copying: 'cpy ” 3-343.4.8 Setting up basic function codes quickly “Quick Setup: *fnc ” 3-383.5 Alarm Mode 3-403.5.1 Releasing the alarm and switching to Running mode 3-403.5.2 Displaying the alarm history 3-403.5.3 Displaying the status of inverter at the time of alarm 3-403.5.4 Switching to Programming mode 3-40

TEST RUN PROCEDURE

Chapter 4

4.1 Test Run Procedure Flowchart 4-14.2 Checking Prior to Powering On 4-24.3 Powering ON and Checking 4-34.4 Destination setting 4-44.5 Switching the Applicable Motor Rating (ND, HD, HND and HHD Modes) 4-64.6 Selecting a Desired Motor Drive Control 4-84.6.1 V/f control with slip compensation inactive for IM 4-84.6.2 Vector control without speed sensor (Dynamic torque vector) for IM 4-84.6.3 V/f control with slip compensation active for IM 4-94.6.4 V/f Control with speed sensor for IM 4-94.6.5 V/f Control with speed sensor with Auto Torque Boost for IM 4-94.6.6 Vector Control with speed sensor for IM 4-94.6.7 Vector Control without speed sensor and magnetic pole position sensor for PMSM 4-104.7 Performance Comparison for Drive Controls (Summary) 4-114.8 Configuring Function Codes for Drive Controls 4-124.8.1 Driving an Induction Motor (IM) 4-13[ 1 ] Driving a non-Fuji motor or Fuji non-standard IM under the V/f control 4-13[ 2 ] Driving a Fuji general-purpose IM under the V/f control 4-14[ 3 ] Driving an IM under the V/f control with speed sensor 4-15[ 4 ] Driving a non-Fuji motor or Fuji non-dedicated IM under vector control

with/without speed sensor 4-16[ 5 ] Driving a Fuji dedicated IM (MVK series) under vector control with speed sensor 4-204.8.2 Driving a permanent magnet synchronous motor (PMSM) without pole sensor

and magnetic pole position sensor 4-21[ 1 ] Driving a non-Fuji PMSM 4-21[ 2 ] Driving a Fuji dedicated PMSM (GNB2 series) 4-26

4.10.2 Setting up a frequency command with an external potentiometer 4-304.10.3 Setting up a frequency command with multistep frequency selection 4-314.11 Selecting a Run Command Source 4-324.11.1 Setting up a run command from the keypad 4-324.11.2 Setting up a run command with digital input signals (terminals [FWD] and [REV]) 4-32

FUNCTION CODES

Chapter 5

5.1 Function Codes Overview 5-15.2 Function Codes Table 5-25.2.1 Supplementary note 5-25.2.2 Function codes table 5-45.2.3 Factory default value per applicable electric motor capacitance 5-365.2.4 Motor constants 5-37[ 1 ] When Fuji standard motor 8-series, or other motors are selected by motor selection

(Function code P99/ A39 = 0 or 4) 5-37[ 2 ] When HP rating motor is selected by motor selection (Function code P99/A39 = 1) 5-415.3 Description of Function Codes 5-455.3.1 F codes (Basic functions) 5-45[ 1 ] Frequency setting by keypad (F01 = 0 (Factory default state), 8) 5-47[ 2 ] Setting up a reference frequency using analog input (F01 = 1 to 3, 5) 5-48[ 3 ] Frequency setting by digital input signal “UP”/“DOWN” (F01=7) 5-54[ 4 ] Frequency setting using digital inputs (option DIO interface card) (F01 = 11) 5-55[ 5 ] Frequency setting using pulse train input (F01 = 12) 5-555.3.2 E codes (Extension terminal functions) 5-1005.3.3 C codes (Control functions) 5-1395.3.4 P codes (Motor 1 parameters) 5-1485.3.5 H codes (High performance functions) 5-155[ 1 ] Measuring the capacitance of DC link bus capacitor in comparison with initial one

at shipment 5-171[ 2 ] Measuring the capacitance of DC link bus capacitor under ordinary operating conditions

at power shutdown 5-1725.3.6 A codes (Motor 2 parameters) 5-1935.3.7 b, r codes (Speed control 3 and 4 parameters) 5-1965.3.8 J codes (Applied functions) 5-197[ 1 ] PID command with the / keys on the keypad (J02 = 0, factory default) 5-198[ 2 ] PID command by analog inputs (J02 = 1) 5-199[ 3 ] PID command with UP/DOWN control (J02 = 3) 5-201[ 4 ] PID command via communications link (J02 = 4) 5-201[ 5 ] Overload stop function 5-213[ 6 ] Brake control signal 5-214[ 7 ] Positioning control with pulse counter 5-217[ 8 ] Servo lock 5-2265.3.9 d codes (Applied functions 2) 5-228[ 1 ] Speed control 5-228[ 2 ] Master-follower operation 5-2385.3.10 U codes (Customizable logic operation) 5-2485.3.11 U1 codes (Customizable logic operation) 5-2735.3.12 y codes (Link functions) 5-277

TROUBLESHOOTING

Chapter 6

6.1 Protective Function 6-16.2 Before Proceeding with Troubleshooting 6-2

[ 6 ] ef Ground fault 6-7[ 7 ] er1 Memory error 6-7[ 8 ] er2 Keypad communications error 6-8[ 9 ] er3 CPU error 6-8[ 10 ] er4 Option communications error 6-8[ 11 ] er5 Option error 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 6-11

[ 16 ] ere Speed inconsistency / Excessive speed deviation 6-12[ 17 ] erf Data saving error during undervoltage 6-13[ 18 ] erh Hardware error 6-13[ 19 ] ero Positioning control error 6-13[ 20 ] err Simulated failure 6-14

[ 21 ] ert CAN communications failure 6-14

[ 22 ] fus DC fuse-blowing 6-14

[ 23 ] lin Input phase loss 6-15[ 24 ] lu Undervoltage 6-15[ 25 ] 0cn Instantaneous overcurrent 6-16[ 26 ] 0h1 Cooling fin overheat 6-17[ 27 ] 0h2 External alarm 6-17[ 28 ] 0h3 Inverter internal overheat 6-17[ 29 ] 0h4 Motor protection (PTC thermistor) 6-18

[ 30 ] 0h6 Charging resistor overheat 6-18

[ 31 ] 0ln Motor overloads 1 to 2 6-19

[ 32 ] 0lu Inverter overload 6-20[ 33 ] 0pl Output phase-failure detection 6-20[ 34 ] 0s Overspeed protection 6-21[ 35 ] 0un Overvoltage 6-21[ 36 ] pbf Charge circuit fault 6-22

[ 37 ] pg PG wire break 6-22

6.4 If the “Light Alarm” Indication (l-al) Appears on the LED Monitor 6-236.5 When Codes Other Than Alarm Codes and Light Alarm Indication (l-al) are Displayed 6-246.5.1 Abnormal motor operation 6-24[ 1 ] The motor does not rotate 6-24[ 2 ] The motor rotates, but the speed does not increase 6-26[ 3 ] The motor runs in the opposite direction to the command 6-27[ 4 ] Speed fluctuation or current oscillation (e.g., hunting) occurs during running

at constant speed 6-28

6.5.2 Problems with inverter settings 6-32[ 1 ] Nothing appears on the LED monitor 6-32[ 2 ] The desired menu is not displayed 6-32[ 3 ] Display of under bars ( ) 6-33[ 4 ] Display of center bars ( ) 6-33[ 5 ] c ] Display of parenthesis 6-33[ 6 ] Data of function codes cannot be changed 6-34[ 7 ] Function code data are not changeable (change from link functions) 6-34[ 8 ] Display of underbars and En ( en) 6-35

MAINTENANCE AND INSPECTION

Chapter 7

7.1 Inspection Interval 7-17.2 Daily Inspection 7-27.3 Periodic Inspection 7-37.3.1 Periodic inspection 1 Before the inverter is powered ON or after it stops running 7-37.3.2 Periodic inspection 2 When the inverter is ON or it is running 7-47.4 List of Periodic Replacement Parts 7-57.4.1 Judgment on service life 7-6[ 1 ] Measuring the capacitance of DC link bus capacitor in comparison with initial one

at shipment 7-7[ 2 ] Measuring the capacitance of the DC link bus capacitor under ordinary operating conditions 7-8[ 3 ] Early warning of lifetime alarm 7-87.5 Measurement of Electrical Amounts in Main Circuit 7-97.6 Insulation Test 7-107.7 Inquiries about Product and Guarantee 7-117.7.1 When making an inquiry 7-117.7.2 Product warranty 7-11[ 1 ] Free of charge warranty period and warranty range 7-11[ 2 ] Exclusion of liability for loss of opportunity, etc 7-12[ 3 ] Repair period after production stop, spare parts supply period (holding period) 7-12[ 4 ] Transfer rights 7-12[ 5 ] Service contents 7-12[ 6 ] Applicable scope of service 7-12

BLOCK DIAGRAMS FOR CONTROL LOGIC

Chapter 8

8.1 Meanings of Symbols Used in the Control Block Diagrams 8-18.2 Frequency Setting Section 8-28.3 Operation Command Section 8-58.4 PID Control Section (for Processing) 8-68.5 PID Control Section (for Dancer) 8-78.6 Control Section 8-88.6.1 V/f control 8-8[ 1 ] Common 8-8[ 2 ] Without speed sensor 8-9[ 3 ] With speed sensor 8-108.6.2 Vector Control 8-11[ 1 ] Common 8-11[ 2 ] Torque command / Torque limit 8-12[ 3 ] Speed control / Torque control 8-13[ 4 ] Speed limit and Over speed protection processing 8-14[ 5 ] For IM 8-15[ 6 ] For PMSM 8-16

[ 3 ] RS-485 communication port 2 (terminal block) (only for FRN-E2■-2/4/7GB, -4C) 9-49.1.3 Connection method 9-59.1.4 RS-485 connection devices 9-8[ 1 ] Converter 9-8[ 2 ] Requirements for the cable (COM port 1: for RJ-45 connector) 9-9[ 3 ] Requirements for the cable (COM port 2: for RS-485 connector) 9-9[ 4 ] Branch adapter for multi-drop 9-99.1.5 RS-485 noise suppression 9-99.2 CANopen Communication 9-109.2.1 Modes 9-109.2.2 Connection method 9-11[ 1 ] Basic connection configuration 9-11[ 2 ] Terminal mode 9-129.2.3 Inverter function codes related to CANopen setting 9-139.2.4 Procedures to establish CANopen communication 9-159.2.5 PDO protocol 9-16[ 1 ] About PDO protocol 9-16[ 2 ] Receive PDO (from master to inverter) 9-17[ 3 ] Transmit PDO (from inverter to master) 9-19[ 4 ] Communication parameters of receive PDO 9-20[ 5 ] Communication parameters of transmit PDO 9-21[ 6 ] Changing PDO (RPDO/TPDO) mapping entry 9-229.2.6 SDO protocol 9-23[ 1 ] About SDO 9-23[ 2 ] Response on SDO error 9-239.2.7 Other services 9-249.2.8 Object list 9-25[ 1 ] Objects in the communication profile area 9-25[ 2 ] Objects in the profile area specific to Fuji Electric 9-319.2.9 Standard device profile area 9-329.2.10 Inverter operation in CANopen communication 9-33[ 1 ] Operation according to CANopen’s drive profile (DSP 402) 9-33[ 2 ] Operation according to the inverter function code S06 9-389.2.11 Heartbeat and Node Guarding 9-42[ 1 ] Heartbeat 9-42[ 2 ] Node Guarding 9-439.2.12 Behavior upon detection of CANopen network disconnection 9-44[ 1 ] Related object and function code list 9-44[ 2 ] Restart from CANopen network disconnection failure 9-469.2.13 Alarm code list 9-479.2.14 Other points to note 9-48

9.3.2 Connection 9-519.3.3 Function overview 9-51[ 1 ] Configuring inverter’s function code 9-51[ 2 ] Multi-monitor 9-52[ 3 ] Running status monitor 9-53[ 4 ] Test-running 9-54[ 5 ] Real-time trace 9-55[ 6 ] Historical trace 9-56

SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES

Chapter 10

10.1 Motor Output Torque Characteristics 10-110.2 Selection Procedure 10-310.3 Equations for Selections 10-610.3.1 Load torque during constant speed running 10-6[ 1 ] General equation 10-6[ 2 ] Obtaining the required force F 10-610.3.2 Acceleration and deceleration time calculation 10-8[ 1 ] Calculation of moment of inertia 10-8[ 2 ] Calculation of the acceleration time 10-10[ 3 ] Calculation of the deceleration time 10-11[ 4 ] Calculating non-linear acceleration/deceleration time 10-11[ 5 ] Calculating non-linear deceleration time 10-1210.3.3 Heat energy calculation of braking resistor 10-13[ 1 ] Calculation of regenerative energy 10-1310.3.4 Calculating the RMS rating of the motor 10-1410.4 Selecting an Inverter Drive Mode (ND/HD/HND/HHD) 10-1510.4.1 Precaution in making the selection 10-1510.4.2 Guideline for selecting inverter drive mode and capacity 10-16

SELECTING PERIPHERAL EQUIPMENT

Chapter 11

11.1 Configuring the FRENIC-Ace 11-111.2 Currents Flowing Across the Inverter Terminals 11-211.3 Molded Case Circuit Breaker (MCCB), Residual-current-operated Protective Device (RCD)/

Earth Leakage Circuit Breaker (ELCB) and Magnetic Contactor (MC) 11-811.3.1 Function overview 11-811.3.2 Connection example and criteria for selection of circuit breakers 11-911.4 Surge Killers for L-load 11-1511.5 Arresters 11-1611.6 Surge Absorbers 11-1711.7 Filtering Capacitors Suppressing AM Radio Band Noises 11-1811.8 Braking Resistors (DBRs) and Braking Units 11-1911.8.1 Selecting a braking resistor 11-19[ 1 ] Selection procedure 11-19[ 2 ] Notes on selection 11-1911.8.2 Braking resistors (DBRs) 11-20[ 1 ] Standard model 11-20[ 2 ] 10%ED model 11-2011.8.3 Braking units 11-2111.8.4 Specifications 11-2211.8.5 External dimensions 11-3111.9 Power Regenerative PWM Converters, RHC Series 11-3311.9.1 Overview 11-33

11.12 Surge Suppression Unit (SSU) 11-5511.13 Output Circuit Filters (OFLs) 11-5611.14 Zero-phase Reactors for Reducing Radio Noise (ACLs) 11-5811.15 External Cooling Fan Attachments 11-5911.16 External Frequency Command Potentiometer 11-6111.17 Extension Cable for Remote Operation 11-6211.18 Frequency Meters 11-6311.19 Options for communication and operation overview 11-6411.19.1 Mounting adapter ( for communication option card) 11-6411.19.2 Communication option cards (required mounting adapter required) 11-6411.19.3 Terminal block type options 11-6511.19.4 Option keypad 11-6511.20 DeviceNet communications card (OPC-DEV) 11-6611.20.1 DeviceNet specifications 11-6611.21 CC-Link communications card (OPC-CCL) 11-6711.21.1 CC-Link specifications 11-6711.22 Digital I/O interface card (OPC-DIO) 11-6811.23 Analog interface card (OPC-AIO) 11-7011.24 RS-485 communication card (OPC-E2-RS) 11-7311.25 PG interface card (OPC-E2-PG3) 11-7511.25.1 Interface specifications (feedback side, PG interface) 11-7511.25.2 Interface specifications (command side, pulse train interface) 11-7611.25.3 Constraints on standard control circuit terminal 11-7611.25.4 Terminal functions 11-7711.25.5 Connection diagram 11-7711.25.6 Voltage selection switch / Power supply selection jumper 11-7811.26 PG interface card (OPC-E2-PG) 11-7911.26.1 Interface specifications (feedback side, PG interface) 11-7911.26.2 Interface specifications (command side, pulse train interface) 11-7911.26.3 Constraints on standard control circuit terminal 11-8011.26.4 Terminal functions 11-8011.26.5 Connection diagram 11-8111.26.6 Power supply selection jumper 11-8111.27 Simple keypad with USB port (TP-E1U) 11-8211.28 Multi functional keypad (TP-A1-E2C) 11-8311.29 FRENIC Visual Customizer 11-8411.29.1 Overview 11-8411.29.2 Specifications 11-8411.29.3 Functions 11-8411.29.4 Main Window 11-85

12.2.1 ND-mode inverters for general load 12-18 12.2.2 HD-mode inverters for heavy duty load 12-18 12.2.3 HND-mode inverters for general load 12-19 12.2.4 HHD-mode inverters for heavy duty load 12-20 12.3 Common Specifications 12-21

EXTERNAL DIMENSIONS

Chapter 13

13.1 Standard Model (FRN0069E2S-2/ FRN0044E2S-4/ FRN0011E2S-7 or below) 13-1 13.2 Standard / EMC Filter Built-in Type (FRN0088E2■-2/ FRN0059E2■-4 or above) 13-6 13.3 EMC Filter Built-in Type (FRN0069E2E-2/ FRN0044E2E-4/ FRN0012E2E-7 or below) 13-14 13.4 Keypad 13-17

APPENDICES

Appendix A Trouble-free Use of Inverters (Notes on electrical noise) 1

A.1 Effect of inverters on other devices 1

[ 1 ] Effect on AM radios 1

[ 2 ] Effect on telephones 1

[ 3 ] Effect on proximity switches 1

[ 4 ] Effect on pressure sensors 1

[ 5 ] Effect on position detectors (pulse encoders) 1

A.2 Noise 2

[ 1 ] Inverter noise 2

[ 2 ] Types of noise 3

A.3 Measures 5

[ 1 ] Noise prevention prior to installation 5

[ 2 ] Implementation of noise prevention measures 5

[ 3 ] Noise prevention examples 8

Appendix B Japanese Guideline for Suppressing Harmonics by Customers Receiving High Voltage or Special High Voltage (General-purpose inverter) 12

B.1 Application to general-purpose inverters 12

[ 1 ] Guideline for suppressing harmonics in home electric and general-purpose appliances 12

[ 2 ] Guideline for suppressing harmonics by customers receiving high voltage or special high voltage 12

B.2 Compliance to the harmonic suppression for customers receiving high voltage or special high voltage 13

[ 1 ] Calculation of equivalent capacity (Pi) 13

[ 2 ] Calculation of Harmonic Current 14

[ 3 ] Examples of calculation 16

Appendix C Effect on Insulation of General-purpose Motors Driven with 400 V Class Inverters 17

C.1 Generating mechanism of surge voltages 17

C.2 Effect of surge voltages 18

C.3 Countermeasures against surge voltages 19

[ 1 ] Using a surge suppressor unit, SSU (Patent pending) 19

[ 2 ] Suppressing surge voltages 19

[ 3 ] Using motors with enhanced insulation 19

C.4 Regarding existing equipment 20

[ 1 ] In case of a motor being driven with 400 V class inverter 20

[ 2 ] In case of an existing motor driven using a newly installed 400 V class inverter 20

Appendix D Inverter Generating Loss 21

Appendix E Conversion from SI Units 22

E.1 Conversion of units 22

E.2 Calculation formulas 23

G.3 Compliance with UL Standards and Canadian Standards (cUL certification) ( ) 39

G.4 Compliance with Functional Safety Standard 45

[ 1 ] General 45

[ 2 ] Notes for compliance to Functional Safety Standard 47

G.5 Compliance with the Radio Waves Act (South Korea) ( ) 48

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■-4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

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

• 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 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 this 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

• 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

• 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

• 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

Disposal

• Treat the inverter as an industrial waste when disposing of it

Otherwise injuries could occur

GENERAL PRECAUTIONS

Drawings in this manual may be illustrated without covers or safety shields for explanation of detail parts Restore the covers and shields in the original state and observe the description in the manual before starting operation

Icons

The following icons are used throughout this manual

This icon indicates information which, if not heeded, can result in the inverter not operating to full efficiency, as well as information concerning incorrect operations and settings which can result inaccidents

This icon indicates information that can be useful when performing certain settings or operations

 This icon indicates a reference to more detailed information

Chapter 1 BEFORE USE

This chapter explains the items to be checked before the use of the inverter

Contents 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 ··· 1-5 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 1.3.3 Precautions for connection of peripheral equipment ··· 1-8 [ 1 ] Phase-advancing capacitors for power factor correction ··· 1-8 [ 2 ] Power supply lines (Application of a DC/AC reactor) ··· 1-8 [ 3 ] DC reactor (DCR) for correcting the inverter input power factor

(for suppressing harmonics) ··· 1-8 [ 4 ] PWM converter for correcting the inverter input power factor ··· 1-8 [ 5 ] Molded case circuit breaker (MCCB) /

residual-current-operated protective device (RCD) /

earth leakage circuit breaker (ELCB) ··· 1-9 [ 6 ] Magnetic contactor (MC) in the inverter input (primary) circuit ··· 1-9 [ 7 ] Magnetic contactor (MC) in the inverter output (secondary) circuit ··· 1-9 [ 8 ] Surge absorber/surge killer ··· 1-9 1.3.4 Noise reduction ··· 1-10 1.3.5 Leakage current ··· 1-10 1.3.6 Precautions in driving a permanent magnet synchronous motor (PMSM) ··· 1-10

1.1 Acceptance Inspection (Nameplates and Inverter Type)

Unpack the package and check the following:

(1) An inverter and the following accessories are contained in the package

Accessories - DC reactor (for ND-mode inverters of FRN0139E2■-4 or above, HD/HND-mode inverters of

FRN0168E2■-4 or above, and HHD-mode inverters of FRN0203E2■-4 or above) (Not included with the FRN****E2■-4C(china model)

- Keypad rear cover (with three screws for securing the keypad)

- Instruction manual

- CD-ROM (containing the FRENIC-Ace User's Manual)

- Wiring guide (for FRN0012E2■-4 or below, FRN0020E2■-2 or below, FRN0011E2■-7

or below) (2) The inverter has not been damaged during transportation—there should be no dents or parts missing

(3) The inverter is the type you ordered You can check the type and specifications on the main nameplate (The

main and sub nameplates are attached to the inverter as shown on Figure 1.2-1.)

(a) Main Nameplate (b) Sub Nameplate

Figure 1.1-1 Nameplates

TYPE: Type of inverter

Figure 1.1-2 Type of inverter

HD mode : Designed for heavy duty load applications

Overload capability: 150% for 1 min

HND mode : Designed for general load applications

Overload capability: 120% for 1 min

HHD mode : Designed for heavy duty load applications

Overload capability: 150% for 1 min and 200% for 0.5 s

SOURCE : Number of input phases (three-phase: 3PH), input voltage, input frequency, input current

OUTPUT : Number of output phases, rated output voltage, output frequency range, rated output capacity,

rated output current, and overload capability

SCCR : Short-circuit capacity

MASS : Mass of the inverter in kilogram

SER No : Product number

6 8 A 1 2 3 A 0 5 7 9 E BB 6 0 1

Production week This indicates the week number that is numbered from 1st week of January

The 1st week of January is indicated as '01'

Production year: Last digit of year Product version

: Compliance with European Standards (See Appendix G Section G-1)

: Compliance with UL Standards and Canadian Standards (cUL certification)

(See Appendix G Section G-2)

: Compliance with the Radio Waves Act (South Korea) (See Appendix G Section G-3)

: Compliance with Russian Standards

If you suspect the product is not working properly or if you have any questions about your product, contact your Fuji Electric representative

1.2 External View and Terminal Blocks

(1) Outside and inside views

Keypad enclosure (can be opened) Internal air circulation fan

Main circuit terminal block Wiring guide Front cover

mounting screw

Term cover

Keypad Warning plate

Main nameplate

Term cover mounting screw

Control circuit terminal block Wiring guide

Term cover

Main circuit terminal block

Control circuit terminal block

(a) FRN0006E2■-4G (b) FRN0203E2■-4G

Figure 1.2-2 Warning Plates and Label

1.3 Precautions for Using Inverters

This section provides precautions in introducing inverters, e.g precautions for installation environment, power

supply lines, wiring, and connection to peripheral equipment Be sure to observe those precautions

1.3.1 Usage environment

Install the inverter in an environment that satisfies the requirements listed in Table 1.3-1

Table 1.3-1 Usage Environment Item Specifications Site location Indoors

Ambient temperature Standard（Open Type）

-10 to +50C (14 to 122F) (HHD/HND spec.) (Note 1) -10 to +40C (14 to 104F) (HD/ND spec.)

NEMA/UL Type1 -10 to +40C (14 to 104F) (HHD/HND spec.) -10 to +30C (14 to 86F) (HD/ND spec.) Relative humidity 5 to 95% RH (No condensation)

Atmosphere The inverter must not be exposed to dust, direct sunlight, corrosive gases, flammable

gases, oil mist, vapor or water drops

Pollution degree 2 (IEC60664-1) (Note 2)

The atmosphere can contain a small amount of salt (0.01 mg/cm2 or less per year)

The inverter must not be subjected to sudden changes in temperature that will cause condensation to form

Altitude 1,000 m (3,300 ft) max (Note 3)

Atmospheric pressure 86 to 106 kPa

Vibration FRN0115E2■-2 or below

FRN0203E2■-4 or below FRN0011E2■-7 or below

2 m/s2 20 to less than 55 Hz 1 m/s2 55 to less than 200 Hz

1 m/s2 55 to less than 200 Hz

(Note 1) When inverters are mounted side-by-side without any clearance between them (FRN0011E2■-7 /

FRN0115E2■-2 / FRN0072E2■-4 or below), the ambient temperature should be within the range

from -10 to +40C

(Note 2) Do not install the inverter in an environment where it may be exposed to lint, cotton waste or moist dust or

dirt which will clog the heat sink of the inverter If the inverter is to be used in such an environment, install

it in a dustproof panel of your system

(Note 3) If you use the inverter in an altitude above 1,000 m (3,300 ft), you should apply an output current derating

factor as listed in Table 1.3-2

Table 1.3-2 Output Current Derating Factor in Relation to Altitude

Any of the following measures may be necessary

- Mount the inverter in a sealed panel with IP6X or air-purge mechanism

- Place the panel in a room free from influence of the gases

Paper manufacturing, sewage disposal, sludge treatment, tire

manufacturing, gypsum manufacturing, metal processing, and a particular process in textile factories

Any of the following measures may be necessary

- Mount the inverter in a sealed panel

- Place the panel in a room free from influence of the conductive dust

Wiredrawing machines, metal processing, extruding machines, printing presses, combustors, and industrial waste treatment

A lot of fibrous or

paper dust

Fibrous or paper dust accumulated on the heat sink lowers the cooling effect

Entry of dust into the inverter causes the electronic circuitry

in panel engineering design

- Employ external cooling when mounting the inverter in a panel for easy maintenance and perform periodical maintenance

Textile manufacturing and paper manufacturing

High humidity or dew

condensation

In an environment where a humidifier is used or where the air conditioner is not equipped with a dehumidifier, high humidity or dew condensation results, which causes a short-circuiting or malfunction

of electronic circuitry inside the inverter

- Put a heating module such as a space heater in the panel

Outdoor installation Film manufacturing line, pumps and food processing.

or blasting at a construction site, the inverter structure gets damaged

- Insert shock-absorbing materials between the mounting base of the inverter and the panel for safe mounting

Installation of an inverter panel on a carrier or self-propelled machine Ventilating fan at a construction site or a press machine

Fumigation for export

packaging

Halogen compounds such as methyl bromide used in fumigation corrodes some parts inside the inverter

- When exporting an inverter built in

a panel or equipment, pack them in

a previously fumigated wooden crate

- When packing an inverter alone for export, use a laminated veneer lumber (LVL)

Exporting

The storage environment in which the inverter should be stored after purchase differs from the usage environment

Store the inverter in an environment that satisfies the requirements listed below

Table 1.3-3 Storage and Transport EnvironmentsItem Specifications

Storage temperature *1 During transport: -25 to +70C (-13 to +158F)

Places not subjected to abrupt temperature changes or condensation

or freezing

During storage: -25 to +65C (-13 to +153F) Relative humidity 5 to 95% RH *2

Atmosphere The inverter must not be exposed to dust, direct sunlight, corrosive or flammable gases,

oil mist, vapor, water drops or vibration The atmosphere must contain only a low level of salt (0.01 mg/cm2 or less per year)

Atmospheric pressure 86 to 106 kPa (during storage)

70 to 106 kPa (during transportation)

*1 Assuming comparatively short time storage, e.g., during transportation or the like

*2 Even if the humidity is within the specified requirements, avoid such places where the inverter will be

subjected to sudden changes in temperature that will cause condensation or freezing

Precautions for temporary storage

(1) Do not leave the inverter directly on the floor

(2) If the environment does not satisfy the specified requirements listed in Table 1.3-3, wrap the inverter in an

airtight vinyl sheet or the like for storage

(3) If the inverter is to be stored in a high-humidity environment, put a drying agent (such as silica gel) in the

airtight package described in (2) above

[ 2 ] Long-term storage

The long-term storage method of the inverter varies largely according to the environment of the storage site

General storage methods are described below

(1) The storage site must satisfy the requirements specified for temporary storage

However, for storage exceeding three months, the surrounding temperature range should be within the range

from -10 to +30°C (14 to 86°F) This is to prevent electrolytic capacitors in the inverter from deterioration

(2) The package must be airtight to protect the inverter from moisture Add a drying agent inside the package to

maintain the relative humidity inside the package within 70%

(3) If the inverter has been installed to the equipment or panel at construction sites where it may be subjected to

humidity, dust or dirt, then temporarily remove the inverter and store it in the environment specified in Table

1.3-3

Precautions for storage over 1 year

If the inverter has not been powered on for a long time, the property of the electrolytic capacitors may deteriorate

Power the inverters on once a year and keep the inverters powering on for 30 to 60 minutes Do not connect the

inverters to the load circuit (secondary side) or run the inverter

operation

An overvoltage trip that occurs when the inverter is stopped or running with a light load is assumed to be due to surge current generated by open/close of phase-advancing capacitors in the power system An optional DC/AC reactor (DCR/ACR) is recommended as a measure to be taken at the inverter side

Inverter input current to an inverter contains harmonic components that may affect other motors and phase-advancing capacitors on the same power supply line If the harmonic components cause any problems, connect a DCR/ACR to the inverter In some cases, it is necessary to insert a reactor in series with the phase-advancing capacitors

Use a DC reactor (DCR) when the capacity of the power supply transformer is 500 kVA or more and is 10 times or more the inverter rated capacity or when there are thyristor-driven loads If no DCR is used, the percentage-reactance of the power supply decreases, and harmonic components and their peak levels increase These factors may break rectifiers or capacitors in the converter section of the inverter, or decrease the capacitance of the capacitors

If the input voltage unbalance rate is between 2% and 3%, use an optional AC reactor (ACR)

67

×(V)voltageaveragephase

Three

-(V)voltageMin

(V)voltageMax

=(%)unbalance

(for suppressing harmonics)

To correct the inverter input power factor (to suppress harmonics), use a DCR Using a DCR increases the reactance of inverter’s power source so as to decrease harmonic components on the power source lines and correct the power factor of the inverter

DCR models Input power factor Remarks

DCR2/4-/A/B Approx 90% to 95% The last letter identifies the capacitance

DCR2/4-C Approx 86% to 90% Exclusively designed when applying with motors with a rated capacity of 37 kW or above

• Select a DCR matching not the inverter capacity but the rated capacity of the applied motor Applicable reactors differ depending upon the selected ND, HD, HND or HHD mode even on the same type of inverters

• For applied motors of 75 kW or above, be sure to connect a DCR to the inverter

Using a PWM converter (High power-factor, regenerative PWM converter, RHC series) corrects the inverter power factor up to nearly “1.”

When combining an inverter with a PWM converter, disable the main power down detection by setting the function code H72 to “0” (default) If the main power down detection is enabled (H72 = 1, factory default), the inverter interprets the main power as being shut down, ignoring an entry of a run command

[ 5 ] Molded case circuit breaker (MCCB) / residual-current-operated protective device

(RCD) / earth leakage circuit breaker (ELCB)

Install a recommended MCCB or RCD/ELCB (with overcurrent protection) in the primary circuit of the inverter to

protect the wiring Since using an MCCB or RCD/ELCB with a lager capacity than recommended ones breaks the

protective coordination of the power supply system, be sure to select recommended ones Also select ones with

short-circuit breaking capacity suitable for the power source impedance

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

Avoid frequent ON/OFF operation of the magnetic contactor (MC) in the input circuit; otherwise, the inverter failure

may result If frequent start/stop of the motor is required, use FWD/REV terminal signals or the / keys on

the inverter's keypad

The frequency of the MC's ON/OFF should not be more than once per 30 minutes To assure 10-year or longer

service life of the inverter, it should not be more than once per hour

• From the system's safety point of view, it is recommended to employ such a sequence that shuts down

the magnetic contactor (MC) in the inverter input circuit with an alarm output signal ALM issued on

inverter's programmable output terminals The sequence minimizes the secondary damage even if the

inverter breaks

When the sequence is employed, connecting the MC's primary power line to the inverter's auxiliary

control power input makes it possible to monitor the inverter's alarm status on the keypad

• The breakdown of a braking unit or misconnection of an external braking resistor may cause damage

of the inverter's internal parts (e.g., charging resistor) To avoid such a breakdown linkage, introduce an

MC and configure a sequence that shuts down the MC if a DC link voltage establishment signal is not

issued within three seconds after the MC is switched on

For the braking transistor built-in type of inverters, assign a transistor error output signal DBAL on

inverter's programmable output terminals to switch off the MC in the inverter input circuit

If a magnetic contactor (MC) is inserted in the inverter's output (secondary) circuit for switching the motor to a

commercial power or for any other purposes, it should be switched on and off when both the inverter and motor are

completely stopped This prevents the contact point from getting damaged due to a switching arc of the MC The

MC should not be equipped with any main circuit surge killer

Applying a commercial power to the inverter's output circuit breaks the inverter To avoid it, interlock the MC on the

motor's commercial power line with the one in the inverter output circuit so that they are not switched ON at the

same time

Do not install any surge absorber or surge killer in the inverter's output (secondary) lines

- Connect a noise filter to the inverter power wires

- Isolate the power system of the other devices from that of the inverter with an insulated transformer

- Decrease the inverter's carrier frequency (F26) See Note below

(2) If induction or radiated noise generated from the inverter affects other devices:

- Isolate the main circuit wires from the control circuit wires and other devices wires

- Put the main circuit wires through a metal conduit pipe, and connect the pipe to the ground near the

inverter

- Install the inverter into the metal panel and connect the whole panel to the ground

- Connect a noise filter to the inverter's power wires

- Decrease the inverter's carrier frequency (F26) See Note below

(3) When implementing measures against noise generated from peripheral equipment:

- For inverter's control signal wires, use twisted or shielded-twisted wires When using shielded-twisted

wires, connect the shield of the shielded wires to the common terminals of the control circuit

- Connect a surge absorber in parallel with magnetic contactor's coils or other solenoids (if any)

Note: Running a permanent magnet synchronous motor (PMSM) at a low carrier frequency may heat the

permanent magnet due to the output current harmonics, resulting in demagnetization When decreasing the

carrier frequency setting, be sure to check the allowable carrier frequency of the motor

1.3.5 Leakage current

A high frequency current component generated by insulated gate bipolar transistors (IGBTs) switching on/off inside

the inverter produces leakage current through stray capacitance of inverter input and output wires or a motor If any

of the problems listed below occurs, take an appropriate measure against them

Problem Measures

An earth leakage circuit

breaker* that is connected to

the input (primary) side has

tripped

* With overcurrent protection

1) Decrease the carrier frequency See Note below

2) Make the wires between the inverter and motor as short as possible

3) Use an earth leakage circuit breaker with lower sensitivity than the one currently used

4) Use an earth leakage circuit breaker that features measures against the high frequency current component (Fuji SG and EG series)

An external thermal relay was

falsely activated

1) Decrease the carrier frequency See Note below

2) Increase the current setting of the thermal relay

3) Use the electronic thermal overload protection built in the inverter, instead of the external thermal relay

Note: Running a permanent magnet synchronous motor (PMSM) at a low carrier frequency may heat the

permanent magnet due to the output current harmonics, resulting in demagnetization When decreasing the

carrier frequency setting, be sure to check the allowable carrier frequency of the motor

1.3.6 Precautions in driving a permanent magnet synchronous motor (PMSM)

When using a PMSM, note the following

• When using a PMSM other than the Fuji standard synchronous motor (GNB2), consult your Fuji Electric

representative

Chapter 2 INSTALLATION AND WIRING

This chapter describes the important points in installing and wiring inverters

Contents 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/ 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) ··· 2-10 2.2.5 Main circuit terminals ··· 2-12 [ 1 ] Screw specifications ··· 2-12 [ 2 ] Terminal layout diagram (main circuit terminal) ··· 2-15 [ 3 ] Recommended wire size (main circuit terminals) ··· 2-18 [ 4 ] Description of terminal functions (main circuit terminal) ··· 2-40 2.2.6 Control circuit terminals (common to all models) ··· 2-44 [ 1 ] Screw specifications and recommended wire size (control circuit terminals) ··· 2-44 [ 2 ] Terminal layout diagram (control circuit terminal) ··· 2-44 [ 3 ] Description of terminal functions (control circuit terminal) ··· 2-45 2.2.7 Switching connector (types FRN0203E2■-4 or above) ··· 2-53 2.2.8 Operating slide switches ··· 2-55 2.3 Attachment and Connection of Keypad ··· 2-57 2.3.1 Parts required for connection ··· 2-57 2.3.2 Attachment procedure ··· 2-57 2.4 RJ-45 Cover ··· 2-61

Install on non-combustible matter such as metals

Risk of fire exists

(3) Surrounding Space

Secure the space shown in Figure 2.1-1 and Table 2.1-1 When

enclosing FRENIC-Ace in cabinets, be sure to provide adequate

ventilation to the cabinet, as the surrounding temperature may rise Do

not contain it in small enclosures with low heat dissipation capacity

When installing 2 or more units in the same equipment or cabinet,

generally mount them to the side of each other, not above each other

When the inverters are mounted above each other, attach partitioning

boards to prevent that the heat dissipated from the lower inverter affects

the upper inverter

For types FRN0072E2-4, FRN0115E2-2, FRN0011E2-7 or

below and for ambient temperature below 40°C only, the units can be

installed side by side without any spacing between them (30°C or lower

(3.9)

0 *1

400 V class: FRN0085 to 0590E2-4 (1.97)50 (3.9)100

*1 A clearance of 50 mm is required to use RJ45 connector

C: Space in front of the inverter unit

The external cooling installation reduces the generated heat inside the

panel by dissipating approximately 70% of the total heat generated (total

heat loss) by mounting the cooling fins protruding outside the equipment

or cabinet

Installation with external cooling is possible for types FRN0030 to

0115E2■-2 and FRN0022 to 0072E2■-4 by adding attachments

(optional) for external cooling, and for types FRN0085E2■-4 or above

by moving the mounting bases

Figure 2.1-2 Installation with External

Cooling

(Please refer to Chapter 11 Item 11.15 for the external dimensions

drawing of the external cooling attachment (optional))

Prevent lint, wastepaper, wood shavings, dust, metal scrap, and

other foreign material from entering the inverter or from attaching to

the cooling fins

Risk of fire and risk of accidents exist

Figure 2.1-1 Installation Direction

Nm (Ib-in) FRN0085E2■-4

to FRN0168E2■-4 M620 (5 screws on top, 3 screws on bottom) M620 (2 screws on top only) 5.8 (51.3) FRN0203E2■-4 M620 (3 screws on top and bottom each) M612 (3 screws on top only) 5.8 (51.3) FRN0240E2■-4

to FRN0290E2■-4 M512 (7 screws on top and bottom each) M512 (7 screws on top only) 3.5 (31.0) FRN0361E2■-4

to FRN0415E2■-4 M516 (7 screws on top and bottom each) M516 (7 screws on top only) 3.5 (31.0) FRN0520E2■-4

to FRN0590E2■-4 M516 (8 screws on top and bottom each) M516 (8 screws on top only) 3.5 (31.0)

1) Remove all of the mounting base fixation screws and the case attachment screws on the top of the inverter 2) Fix the mounting bases to the case attachment screw holes using the mounting base fixation screws A few screws should remain after changing the position of the mounting bases

3) Change the position of the mounting bases on the bottom side following the procedure in 1) and 2)

Mounting base fixation screw

Mounting base (upper side)

Mounting base (lower side)

Mounting base fixation screw Case attachment screw

Figure 2.1-3 Method to Change the Mounting Base Positions

Use the specified screws in changing the mounting bases

Risk of fire and risk of accidents exist

Select the bolt size, considering the thickness of the mounting feet and installation surface so that the bolt protrudes from the nut by 2 threads or more

Inverter type Inverter fixation screw Tightening torque Nm (Ib-in) 200V class：FRN0030/0040E2■-2

400V class：FRN0022/0029E2■-4 M5 (4 screws) 3.5 (31.0)

2.2.1 Basic connection diagram

Figure 2.2-1 Standard Terminal Block Board (with CAN)

(Note 16)

Figure 2.2-2 Standard Terminal Block Board (Without CAN, With FM2)

(Note 16)

(Note 1) Install recommended circuit breakers (MCCB) or residual-current-operated protective device (RCD)/

earth leakage breakers (ELCB) (with overcurrent protective function) on the inputs of each inverter

(primary side) for wiring protection Do not use breakers which exceed the recommended rated current

(Note 2) Install recommended magnetic contactors (MC) as necessary on each inverter as these will be used to

disconnect the inverter from the power supply separately from the MCCB or RCD / the ELCB

Additionally, when installing coils such as MC or solenoid close to the inverter, connect surge absorbers

in parallel

(Note 3) When it is desired to retain the alarm signal for the activation of the protective function even inverter

main power supply is shut off, or when it is desired continuous display of the keypad, connect this

terminal to the power supply The inverter can be operated without connecting power to this terminal

(applicable for types FRN0059E2■-4/ FRN00088E2■-2 or above)

(Note 4) The terminal does not need to be connected Use this terminal when operating in combination with a

high power factor regenerative PWM converter (RHC series) Applicable for types FRN0203E2■-4 or

above)

(Note 5) Remove the shorting bar between the inverter main circuit terminals P1-P(+) before connecting the

direct current reactor (DCR) (option)

It must be connected in the following cases:

ND mode: Types FRN0139 E2■-4 or above, HD/ HND mode: Types FRN0168E2■-4 or above, HHD

mode: Types FRN0203E2■-4 or above

Use the direct current reactor (option) when the power supply transformer capacity is above 500 kVA

and the transformer capacity is over 10 times the rated capacity of the inverter, or when “thyristor load

exists” in the same power system

(Note 6) Types FRN0011E2■-7/FRN0115E2■-2/ FRN0072E2■-4 or below have built-in braking transistors,

allowing direct connection of braking resistors between P(+)-DB

(Note 7) When connecting braking resistors to types FRN0085E2■-4 or above, always add the braking unit

(option) Connect the braking unit (option) between P(+)-N(-) Auxiliary terminals [1] and [2] have polarity

Please connect as shown in the diagram

(Note 8) This terminal is used for grounding the motor Grounding the motor using this terminal is recommended

in order to suppress inverter noise

(Note 9) Use twisted lines or shielded lines for the control signals

Generally, the shielded line requires grounding, but when the effect of externally induced noise is large,

connecting to [CM] may suppress the effect of noise Separate the line from the main circuit wiring and

do not enclose in the same duct (Separation distance of over 10 cm is recommended.) When crossing

the main circuit wiring, make the intersection perpendicular

(Note 10) The various functions listed for terminals[X1] to [X5](digital inputs), terminals [Y1] to [Y2](transistor

output), and terminal [FM] (monitor output) show the functions assigned as factory default

(Note 11) These are connectors for switching the main circuit For details, refer to “2.2.7 Switching connector

(types FRN0203E2■-4 or above)”

(Note 12) The slide switches on the control printed circuit board define the settings for the inverter operation For

details, refer to “2.2.8 Operating slide switches”

(Note 13) Make the circuit breakers (MCCB) or the magnetic contactors (MC) trip by the thermal relay auxiliary

contacts (manual recovery)

(Note 14) Shorting bars are connected between the safety function terminals [EN1], [EN2], and [PLC] as factory

default Remove the shorting bars when using this function

(Note 15) and are separated and insulated

(Note 16) Charge lamp does not exist in the inverters FRN0069E2■-2/FRN0044E2■-4/FRN0011E2■-7 or

below

Always remove the RS-485 communication cable from the RJ-45 connector before removing the front cover

Risk of fire and risk of accidents exist

1) Loosen the screws of the terminal cover To remove the terminal cover, put your finger in the dimple of the terminal cover and then pull it up toward you

2) Pull out the wiring guide toward you

3) After routing the wires, attach the wiring guide and the terminal cover reversing the steps above

Figure 2.2-3 Removal of the Terminal Cover and the Wiring Guide (for FRN0006E2S-2)

1) Loosen the screws of the terminal cover To remove the terminal cover, put your finger in the dimple of the terminal cover and then pull it up toward you

2) Pull out the wiring guide toward you

3) After routing the wires, attach the wiring guide and the terminal cover reversing the steps above

1) Loosen the screws of the front cover Hold both sides of the front cover with the hands, slide the cover

downward, and pull Then remove it to the upward direction

2) Push the wiring guide upward and pull Let the wiring guide slide and remove it

3) After routing the wires, attach the wiring guide and the front cover reversing the steps above

Figure 2.2-5 Removal of the Front Cover and the Wiring Guide (for FRN0072E2■-4)

1) Loosen the screws of the front cover Hold both sides of the front cover with the hands and slide it upward to

L1/L, L2N(Single-phase) (The inverter will be damaged when power is applied if the power lines are connected to the wrong terminals.)

(3) Always route the ground line to prevent accidents such as electric shock and fire and to reduce noise (4) For the lines connecting to the main circuit terminals, use crimped terminals with insulating sleeves or use crimped terminals in conjunction with insulating sleeves for high connection reliability

(5) Separate the routing of the lines connected to the main circuit input side terminals (primary side) and the output side terminals (secondary side) and the lines connected to the control circuit terminals

The control circuit terminal lines should be routed as far as possible from the main circuit routing Malfunction may occur due to noise

(6) To prevent direct contact with the main circuit live sections (such as the main circuit terminal block), route the control circuit wiring inside the inverter as bundles using cable ties

(7) After removing a main circuit terminal screw, always restore the terminal screw in position and tighten even if lines are not connected

(8) The wiring guide is used to separately route the main circuit wiring and the control circuit wiring The main circuit wiring and the control circuit wiring can be separated Exercise caution for the order of wiring

Case of FRN0006E2S-2 Case of FRN0072E2■-4