Fuji Electric OPC-G1-SX. User manual

ENGLISH
English Version

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ENGLISH
Preface
Thank you for purchasing our SX-bus Communications Card OPC-G1-SX.
Mounting this communications card on your FRENIC-MEGA allows you to connect the FRENIC-MEGA to a Fuji
programmable logic controller MICREX-SX series via SX bus and control it as a slave unit using run and
frequency commands, and accessing function codes.
This instruction manual does not contain the handling instructions of the inverter or the Fuji programmable logic
controller MICREX-SX series. Read through this instruction manual in conjunction with the FRENIC-MEGA
instruction manual and the MICREX-SX user's manuals and be familiar with proper handling and operation of
this product. Improper handling might result in incorrect operation, a short life, or even a failure of this product.
Keep this manual in a safe place.
Related Publications
Listed below are the other materials related to the use of the SX-bus communications card "OPC-G1-SX." Read
them in conjunction with this manual as necessary.
• RS-485 Communication User's Manual
• FRENIC-MEGA Instruction Manual
• User's manuals of the Fuji programmable logic controller MICREX-SX series
The materials are subject to change without notice. Be sure to obtain the latest editions for use.
• Read through this instruction manual and be familiar with the SX-bus communications card before
proceeding with installation, connections (wiring), operation, or maintenance and inspection.
• 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.
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.

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Installation and wiring
• Before starting installation and wiring, turn OFF the power and wait at least five minutes for inverters
with a capacity of 22 kW or below, or at least ten minutes for inverters with a capacity of 30 kW 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).
• Qualified electricians should carry out wiring.
Otherwise, an electric shock could occur.
• Do not use the product that is damaged or lacking parts.
Doing so could cause a fire, an accident, or injuries.
• Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into
the inverter and the communications card.
Otherwise, a fire or an accident might result.
• Incorrect handling in installation/removal jobs could cause a failure.
A failure might result.
• Noise may be emitted from the inverter, motor and wires. Implement appropriate measure to prevent
the nearby sensors and devices from malfunctioning due to such noise.
Otherwise, an accident could occur.
Operation
• Be sure to install the front cover before turning the inverter's 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 an electric shock.
• If you configure the function codes wrongly or without completely understanding FRENIC-MEGA
Instruction Manual and the FRENIC-MEGA User's Manual, the motor may rotate with a torque or at a
speed not permitted for the machine. Confirm and adjust the setting of the function codes before
running the inverter.
Otherwise, an accident 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 with a capacity of 22 kW or below, or at least ten minutes for inverters with a
capacity of 30 kW 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.
• 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.

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Disposal
• Treat the communications card as an industrial waste when disposing of it.
Otherwise injuries could occur.
Others
• Never modify the communications card.
Doing so could cause an electric shock or injuries.
Icons
The following icons are used throughout this manual.
This icon indicates information which, if not heeded, can result in the product not operating to full
efficiency, as well as information concerning incorrect operations and settings which can result in
accidents.
This icon indicates information that can prove handy when performing certain settings or operations.
This icon indicates a reference to more detailed information.

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Table of Contents
Preface ..................................................................... 1
Safety precautions ............................................................ 1
Chapter 1 BEFORE USE ................................................... 5
1.1 Acceptance Inspection ............................................ 5
1.2 Applicable Inverters ................................................. 5
Chapter 2 NAMES AND FUNCTIONS ............................... 6
2.1 Parts Names ............................................................ 6
2.2 Station Address Switches (RSW1 and RSW2) ........ 6
2.3 SX-bus Connectors ................................................. 6
2.4 LED Status Indicators .............................................. 7
Chapter 3 INSTALLATION AND REMOVAL OF THIS
COMMUNICATIONS CARD ............................. 8
3.1 Installing the Communications Card ........................ 8
3.2 Removing the Communications Card ...................... 9
Chapter 4 WIRING AND CABLING ................................. 10
4.1 Basic Connection Diagram .................................... 10
4.2 Wiring to Inverter ................................................... 12
Chapter 5 CONFIGURING INVERTER'S FUNCTION
CODES FOR SX-BUS COMMUNICATION .... 13
5.1 Inverter's Function Codes ...................................... 13
5.2 Error Processing for SX-bus Network Breaks ........ 13
5.3 o31 Display Value .................................................. 14
Chapter 6 ESTABLISHING AN SX-BUS
COMMUNICATIONS LINK .............................. 15
Chapter 7 COMMUNICATIONS FORMAT ....................... 21
7.1 Data Allocation in the SX-bus I/O Area of the
Communications Format ........................................ 21
7.2 Details of Communications Format ........................ 22
7.3 Configuring Inverter's Function Codes ................... 24
7.4 Example of Communication Data ........................... 25
Chapter 8 LIST OF INVERTER ALARM CODES ............. 27
Chapter 9 PROTECTIVE FUNCTIONS ........................... 28
Chapter 10 SPECIFICATIONS .......................................... 29
10.1 General Specifications ........................................... 29
10.2 SX-bus Specifications ............................................ 30

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Chapter 1 BEFORE USE
1.1 Acceptance Inspection
Unpack the package and check the following:
(1) A communications card, two screws (M3 8), and the SX-bus Communications Card Instruction Manual
(this document) are contained in the package.
(2) The communications card is not damaged during transportation--no defective parts, dents or warps.
(3) The model name "OPC-G1-SX" is printed on the communications card. (See Figure 2.1.)
If you suspect the product is not working properly or if you have any questions about your product, contact the
shop where you bought the product or your local Fuji branch office.
Neither a terminating connector nor an SX-bus cable comes with this communications card. Those
parts that match the connection distance are necessary. (The terminating connectors that come with
the CPU module of the MICREX-SX series can be used.)
1.2 Applicable Inverters
The SX-bus communications card is applicable to the following inverters and ROM version.
Table 1.1 Applicable Inverters and ROM Version
Series Inverter type Applicable motor rating ROM version
FRENIC-MEGA FRN G1 - All capacities 1000 or later
* The boxes replace alphanumeric letters depending on the nominal applied motor, enclosure, power supply voltage, etc.
To check the inverter's ROM version, use Menu #5 "Maintenance Information" on the keypad. (Refer to the
FRENIC-MEGA Instruction Manual, Chapter 3, Section 3.4.6 "Reading maintenance information."
Display on LED Monitor Item Description
Inverter's ROM version Shows the inverter's ROM version as a 4-digit code.

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Chapter 2 NAMES AND FUNCTIONS
2.1 Parts Names
Figure 2.1 shows the names of the parts on the SX-bus communications card.
(Front) (Back)
Figure 2.1 Names of Parts on SX-bus Communications Card
2.2 Station Address Switches (RSW1 and RSW2)
The station address switches on the communications card are rotary ones (RSW1 and RSW2) that are used to
configure the station address of the communications card on an SX bus. The setting range is from 00 to EE in
hexadecimal.
The station address currently assigned to the inverter can be checked by the function code o31. For details
about o31, refer to Section 5.1.
The station address switches should be accessed with the inverter power OFF. If configured with the
power being ON, the new station address takes effect when the inverter is restarted.
Note 1: When two or more communications cards are used on the same SX bus, the
same station address should not be double assigned.
Note 2: Factory default: RSW1 = 0, RSW2 = 0 (Station address = 00)
Note 3: The function code o31 displays the current station address in decimal. When
configuring the station address with the station address switches, assign it in
hexadecimal.
Figure 2.2 Station Address Switches (RSW1 and RSW2)
2.3 SX-bus Connectors
The SX-bus connectors (IN and OUT) are used to connect the SX-bus cable(s). For details, refer to Chapter 4
"WIRING AND CABLING."
RSW1: Upper bits
RSW2: Lower bits
Screw hole (right)
CN1
SX-bus connector (OUT)
LED status indicators
Screw hole (left)
Positioning
cutout
RSW2
SX-bus connector (IN)
Station address switches
RSW1
Release knob
Model name

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2.4 LED Status Indicators
The communications card has two LED status indicators that indicate the operation status of the
communications card as listed in Table 2.1.
Table 2.1 LED Indicators and Operation Status
LED (Color) LED state Meaning
RUN (Green) ON The SX-bus communications link is established.
(If the ERR LED is also ON, a light alarm has
occurred.)
Flashing Initializing in progress
OFF SX bus power OFF
Inverter power OFF
Inverter being reset
ERR (Red) ON Communications failure
(A heavy alarm or light alarm has occurred.)

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Chapter 3 INSTALLATION AND REMOVAL OF THIS COMMUNICATIONS CARD
Before starting installation and wiring, turn OFF the power and wait at least five minutes for inverters with a
capacity of 22 kW or below, or at least ten minutes for inverters with a capacity of 30 kW 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.
• Do not use the product that is damaged or lacking parts.
Doing so could cause a fire, an accident, or injuries.
• Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into
the inverter and the communications card.
Otherwise, a fire or an accident might result.
• Incorrect handling in installation/removal jobs could cause a failure.
A failure might result.
3.1 Installing the Communications Card
Before mounting the communications card, perform the wiring for the main circuit terminals and control
circuit terminals.
(1) Remove the front cover from the inverter and expose the control printed circuit board (control PCB). As
shown in Figure 3.1, the communications card can be connected to the A-port only, out of three option
connection ports (A-, B-, and C-ports) on the control PCB.
To remove the front cover, refer to the FRENIC-MEGA Instruction Manual, Chapter 2, Section 2.3. For
inverters with a capacity of 30 kW or above, open also the keypad enclosure.
(2) Insert connector CN1 on the back of the communications card (Figure 2.1) into the A-port (CN4) on the
inverter's control PCB. Then secure the communications card with the two screws that come with the card.
(Figure 3.3)
Check that the positioning cutout (shown in Figure 2.1) is fitted on the tab ( in Figure 3.2) and
connector CN1 is fully inserted ( in Figure 3.2). Figure 3.3 shows the communications card correctl
y
mounted.
When the SX-bus communications card is mounted, the B-port can accept only the relay outpu
t
interface card.
(3) Perform wiring to the communications card.
For details, refer to Chapter 4 "WIRING AND
CABLING."
(4) Put the front cover back into place.
To put back the front cover, refer to the FRENIC-MEGA
Instruction Manual, Chapter 2, Section 2.3.
For inverters with a capacity of 30 kW or above, close
also the keypad enclosure.
Figure 3.1 In the case of 0.4 kW

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Fit the positioning cutout of the communications
card over the tab on the inverter to determine the
mounting position.
Insert connector CN1 on the communications
card into the corresponding port on the inverter's
control PCB.
Note: Be sure to follow the order of and .
Inserting CN1 first may lead to insufficient
insertion, resulting in a contact failure.
Figure 3.2 Mounting the Communications Card
Figure 3.3 Mounting Completed
3.2 Removing the Communications Card
Remove the two screws that secure the communications card and pull the release knob (shown above) to take
the communications card out of the inverter.
Tab
(Release knob)

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Chapter 4 WIRING AND CABLING
• Before starting installation and wiring, turn OFF the power and wait at least five minutes for inverters with
a capacity of 22 kW or below, or at least ten minutes for inverters with a capacity of 30 kW 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).
• Qualified electricians should carry out wiring.
Otherwise, an electric shock could occur.
• In general, the covers 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 cover 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.
Failure to observe this precaution could cause an electric shock or an accident.
Noise may be emitted from the inverter, motor and wires. Take appropriate measures to prevent the nearby
sensors and devices from malfunctioning due to such noise.
An accident could occur.
4.1 Basic Connection Diagram
U
V
W
L1/R
L2/S
L3/T
FRENIC-MEGA
OPC-G1-SX
IN
OUT
U
V
W
L1/R
L2/S
L3/T
FRENIC-MEGA MOTOR
OPC-G1-SX
IN
OUT
SX
+ +
+
+
+
+
IN
OUT
If the total cabling length
exceeds 25 m, use an SX-
bus electric repeater unit
(NP2L-RP1).
G
G
MOTOR
SX-bus terminating
connector
SX-bus cable
SX-bus cable
SX-bus terminating
connector
The total SX-bus
cabling length should
be 25 m or less.
Figure 4.1 Basic Connection Diagram

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Figure 4.1 shows the basic connection diagram. When connecting the communications card to an SX bus,
observe the following precautions.
Precautions for SX bus connection
(1) Be sure to use SX-bus dedicated cables.
Model: NP1C-P3 (0.3 m) to NP1C-25 (25 m)
For details about the cable specifications, refer to the MICREX-SX user's manual (Hardware version)
which can be downloaded for free from our website at:
http://www.fujielectric.com/
(2) Before proceeding with connection, make sure that both the MICREX-SX and the inverter are powered OFF.
(3) Put the terminating connectors (that come with the CPU module of the MICREX-SX) in both ends of the SX
bus.
(4) One end of the SX-bus cable should be connected with the OUT SX-bus connector, and the other end, with
the IN connector. The OUT-OUT or IN-IN connection does not enable communication. Route SX-bus cables
so that the bending radius is at least 50 mm.
(5) A maximum of 10 communications cards can be connected to a same SX bus. (The maximum number of
cards connectable decreases depending upon the MICREX-SX system configuration.)
For details, refer to the MICREX-SX user's manual.
Neither a terminating connector nor an SX-bus cable comes with this communications card. Those
parts that match the connection distance are necessary. (The terminating connectors that come with
the CPU module of the MICREX-SX series can be used.)

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4.2 Wiring to Inverter
Route the SX-bus cables as far from the wiring of the main circuit as possible. Otherwise electric noise
may cause malfunctions.
Pass the SX-bus cables between the control circuit terminal block and the front cover.
• For inverters with a capacity of 22 kW or below
In the case of 0.4 kW
• For inverters with a capacity of 30 kW or above
In the case of 75 kW
Figure 4.2 Examples of Wiring

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Chapter 5 CONFIGURING INVERTER'S FUNCTION CODES FOR SX-BUS
COMMUNICATION
5.1 Inverter's Function Codes
Before starting actual inverter operation, configure the inverter's function codes listed in Table 5.1. It is
recommended to configure them before starting SX-bus communication, since an SX-bus network break could
occur immediately after the start of communication.
Table 5.1 Inverter's Function Code Settings Required for SX-bus Communication
Function
codes Description Factory default Function code data Remarks
o27 Select error processing for
SX-bus network breaks 00 to 15 For details about o27
and o28, see Table
5.2.
o28
Set the operation timer to be
used in error processing for
network breaks
0.0 s
0.0 to 60.0 s
o30 Specify SX-bus
communications format 0
0: Standard format
1 to 255: (Specification not allowed.)
For details about the
communications
format, refer to
Chapter 7.
o31 SX-bus station address 0
Do not set anything.
(o31 displays the inverter's station address
currently assigned by the SX bus. Even
writing any data to o31 cannot change this
station address.)
Refer to Section 5.3.
y98 Select run/frequency
command sources 0
Select from the following choices:
y98 Frequency
command source
Run
command source
0 Inverter Inverter
1 SX bus Inverter
2 Inverter SX bus
3 SX bus SX bus
If there is no special
problem with your
system, y98 = 3 is
recommended.
5.2 Error Processing for SX-bus Network Breaks
Inverter's function codes o27 and o28 define error processing that the inverter should perform when it detects
an SX-bus network break, as listed in Table 5.2.
If no run or frequency command via the communications link is enabled, the inverter does not issue ,
performing no error processing.
Table 5.2 Error Processing for SX-bus Network Breaks, Defined by Function Codes o27 and o28
o27 o28 Error Processing
after Detection of SX-bus Network Break Remarks
0, 4 to 9 Invalid Immediately coast to a stop and trip with .
1 0.0 to 60.0 s After the time specified by o28, coast to a stop and trip with .
2 0.0 to 60.0 s If the communications link is restored within the time specified by
o28, ignore the communications error. If a timeout occurs, coast to
a stop and trip with .
3,
13 to 15
Invalid Keep the current operation, ignoring the communications error.
(No trip)
10 Invalid Immediately decelerate to a stop. After the stop, trip with . The inverter's
function code F08
specifies the
deceleration time.
11 0.0 to 60.0 s After the time specified by o28, decelerate to a stop. After the stop,
trip with .
Same as above.
12 0.0 to 60.0 s If the communications link is restored within the time specified by
o28, ignore the communications error. If a timeout occurs,
decelerate to a stop and trip with .
Same as above.

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5.3 o31 Display Value
o31 displays the actual station address of the communications card which is currently assigned by the
connected SX bus. The actual station address may be different from the one configured by the station address
switches (RSW1 and RSW2 described in Section 2.2) since the SX bus has priority over those switches.
Even writing any data to o31 from the keypad or via SX bus cannot change the actual station address or
overwrite the o31 data with the written data.
When the communications card is not connected to the MICREX-SX, the o31 data does not show the actual
station address.
The o31 displays the station address in decimal. When configuring the station address with the station
address switches, assign it in hexadecimal.

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Chapter 6 ESTABLISHING AN SX-BUS COMMUNICATIONS LINK
After confirming that wiring to the SX bus has been completed, establish an SX-bus communications link
between the MICREX-SX and the inverter and start SX-bus communication, using the procedure given in this
chapter.
SX-bus communication enables the MICREX-SX to issue run commands and monitor the inverter's
running status. For details, refer to Chapter 7 "COMMUNICATIONS FORMAT."
This instruction manual contains the minimum descriptions for configuring the communications card. For
details about the MICREX loader, refer to the corresponding MICREX-SX user's manuals.
(1) Checking the version of SX-Programmer Expert (D300win)
SX-Programmer Expert (D300win) is system software for creating programs of the MICREX-SX series.
Only Expert version 3.4.4.1 or later can define the SX-bus communications card.
Choose Help|Info… from the menu bar on the top screen.
Expert version 3.4.4.1 or later *
* If your Expert version is
earlier than 3.4.4.1, consult
your Fuji Electric
representative.

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(2) Adding a module
In the project tree pane in Expert, double-click System_Definition under Physical Hardware.
The system definition window appears as shown below.
Right-click 11 slots Base: to display the pull-down menu and then choose Insert.
Double-click System_Definition.

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The Module insert window appears.
Select items as shown below and then click OK.
The screen returns to the system definition window as shown below.
Check that the inverter FRN-G1 is registered under the System structure in the system definition tree.

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(3) Configuring the I/O group
Allocate the module (inverter) in the MICREX-SX CPU. Incorrect allocation of the I/O group disables
input/output control from the CPU.
In the system definition window, right-click CPU: to display the pull-down menu and then choose
Properties....
The Module properties window appears as shown below.
Click Parameters….