Fuji Electric Frenic Mega Series User manual

24A7-E-0054

High Performance, Multifunction Inverter
User's Manual

Copyright © 2007-2013 Fuji Electric Systems Co., Ltd.
All rights reserved.
No part of this publication may be reproduced or copied without prior written
permission from Fuji Electric Systems Co., Ltd.
Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the
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are trademarks or registered trademarks of their respective holders.
The information contained herein is subject to change without prior notice for improvement.
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.

Safety precautions
i
Preface
This manual provides all the information on the FRENIC-MEGA series of inverters including its operating
procedure, operation modes, and selection of peripheral equipment. Carefully read this manual for proper use.
Incorrect handling of the inverter may prevent the inverter and/or related equipment from operating correctly,
shorten their lives, or cause problems.
The table below lists the other materials related to the use of the FRENIC-MEGA. Read them in conjunction with
this manual as necessary.
Table 1
Name Material No. Description
Catalog 24A1-J-0015
Product scope, features, specifications, external drawings,
and options of the product
Instruction Manual INR-SI47-1668 Acceptance inspection, mounting & wiring of the inverter,
operation using the keypad, running the motor for a test,
troubleshooting, and maintenance and inspection
RS-485 Communication
User's Manual MHT271
Overview of functions implemented by using FRENIC-MEGA
RS-485 communications facility, its communications
specifications, Modbus RTU/Fuji general-purpose inverter
protocol and functions, and related data formats
The materials are subject to change without notice. Be sure to obtain the latest editions for use.
Guideline for Suppressing Harmonics in Home Electric and General-purpose Appliances
Our three-phase, 200 V class series inverters of 3.7 kW or less (FRENIC-MEGA series) were the products of
which were restricted by the "Guideline for Suppressing Harmonics in Home Electric and General-purpose
Appliances" (established in September 1994 and revised in October 1999) issued by the Ministry of Economy,
Trade and Industry. The above restriction, however, was lifted when the Guideline was revised in January 2004.
Since then, the inverter makers have individually imposed voluntary restrictions on the harmonics of their products.
We, as before, recommend that you connect a reactor (for suppressing harmonics) to your inverter. As a reactor,
select a "DC REACTOR" introduced in this manual. For use of the other reactor, please inquire of us about
detailed specifications.
Japanese Guideline for Suppressing Harmonics by Customers Receiving High Voltage or Special
High Voltage
Refer to this manual, Appendix B for details on this guideline.
Preface

Safety precautions
ii
Safety precautions
Read this manual and the FRENIC-MEGA Instruction Manual (that comes with the product) thoroughly before
proceeding with installation, connections (wiring), operation, or maintenance and inspection. Ensure you have
sound knowledge of the product 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.
General Precautions
Figures used in this manual may be drawn with covers and safety guards removed in order to describe hidden
details. When using the product, make sure that these covers and safety guards are installed as specified and
then run the product as directed in this manual.
Purpose
This product is not designed for use in appliances and machinery on which lives depend. Consult your Fuji
Electric representative before considering the FRENIC-MEGA series of inverters for equipment and machinery
related to nuclear power control, aerospace uses, medical uses or transportation. When the product is to be
used with any machinery or equipment on which lives depend or with machinery or equipment which could
cause serious loss or damage should this product malfunction or fail, ensure that appropriate safety devices
and/or equipment are installed.
• The FRENIC-MEGA is designed to drive three-phase induction motors only. It cannot be used to drive
single-phase motors and/or for any other purposes.
Otherwise, a fire could occur.
• The FRENIC-MEGA cannot be used for a purpose where human accidents may be directly concerned (e.g.,
a life support system) without necessary modification.
• Although this product is manufactured under strict quality control, be sure to provide safety measures when
using it in facilities where its failure may cause a serious accident or loss.
Otherwise, an accident could occur.
Installation
• Install the inverter on an uninflammable object.
• Do not install the inverter near an inflammable object.
Otherwise, a fire could occur.
• The enclosure of an inverter of 30 kW or more conforms to IP00 and may touch the terminal block of the
main circuit (where electricity exists). It is also true when the optional DC reactor is used. In such cases take
a measure to prevent a person from easily touching the inverter.
Otherwise, an electric shock or injury could occur.

Safety precautions
iii
• Do not carry the inverter by holding the front cover.
Otherwise, an injury could occur due to a falling inverter.
• Prevent any foreign material (e.g., lint, wastepaper, chippage, dust, metal) from entering into the inside of
the inverter and/or adhering to the cooling fin.
• Use the specified screws when changing the installation legs.
Otherwise, a fire or accident could occur.
• Do not install and/or run an inverter with damaged exterior or internal parts.
Otherwise, a fire, accident, or injury could occur.
Cabling
• 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.
• Insert an MCCB or RCD/ELCB (with overcurrent protection) recommended for each inverter for its input
circuits. Use a recommended MCCB or RCD/ELCB and do not use a device which exceeds the
recommended capacity.
• Be sure to use wires of the specified sizes.
• Tighten the terminals with the specified torque.
• When using multiple combinations of inverters and motors, do not use multi-core cables to accommodate
multiple combinations of cables.
• Do not install any surge killer in the inverter's output (secondary) lines.
• Use an optional 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.
• Implement the Class C or Class D grounding work depending on the input voltage system of the inverter.
• Be sure to ground the grounding wire of the inverter [ G].
Otherwise, an electric shock or fire could occur.
• Cabling must be done by a qualified expert after installing the inverter with its power disconnected.
Otherwise, an electric shock or injury could occur.
• Make sure that the number of phases and rated voltage match those of the connected power supply.
• Do not connect the power supply line to the inverter output terminals ([U], [V], and [W]).
• When connecting a braking resistor, be sure to connect it to the P(+)-DB terminal.
Otherwise, a fire or accident could occur.
• Generally, reinforced insulation is not applied to the insulation sheath of control signal lines. Therefore, if a
control signal line should touch the main circuit where electricity exists, its insulation sheath may get broken.
This may result in applying the high voltage of the main circuit to the control signal line. Make sure that no
control signal line touches the main circuit where electricity exists.
Otherwise, an accident or electrical shock could occur.
• Before changing the switches or touching the control circuit terminal symbol plate, 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.

Safety precautions
iv
• Electric noises occur from the inverter, motor, and wire, causing peripheral sensors and/or devices to
malfunction. Take a measure against the noises to prevent such malfunctioning.
Otherwise, an accident could occur.
• Leakage current from the EMC filter built-in type inverter is relatively large. Make sure that it is correctly
grounded.
Otherwise, an electric shock could occur.
Operation
• Be sure to mount the front cover before turning the power ON. Do not remove the front cover when the
inverter power is ON.
• Do not operate switches with wet hands.
Otherwise, an electric shock could occur.
• If the "auto-reset" function has been specified, the inverter may automatically restart and run the motor
stopped due to a trip fault, depending on the cause of the tripping. Design the machinery so that human
body and peripheral equipment safety is ensured even when the auto-resetting succeeds.
• The motor may run with different acceleration/deceleration time and/or frequency due to stall prevention
function (current limiting), anti-regenerative control, and overload stop. Design the machinery so that safety
is ensured in such cases.
Otherwise, an accident could occur.
• The key on the keypad works only when "Enable keypad" is selected with the function code F02.
Provide an emergency stop switch separately. When the run command source is switched from the keypad
with "Link operation selection" (LE), the key will not work. To enable emergency stop with the key
on the keypad while the external signal terminal is selected as the run command source, select "STOP key
priority" with the function code H96.
• If any of the protective functions has 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, 4, or 5), the
inverter automatically restarts the motor running 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.
Otherwise, an accident or injury could occur.
• Even though the inverter has interrupted power to the motor, if the voltage is applied to the main circuit
input terminals L1/R, L2/S and L3/T, voltage may be output to inverter output terminals U, V, and W.
• When the servo-lock command is ON, the inverter keeps on outputting voltage on output terminals [U], [V]
and [W] even if a run command is OFF and the motor seems to stop.
• Even if the motor stops due to DC braking or pre-excitation, voltage is output to inverter's output terminals
[U], [V], and [W].
Otherwise, an electric shock could occur.
• The inverter can easily accept high-speed operation settings. When changing the speed setting, carefully
check the specifications of motors or equipment beforehand.
Otherwise, an injury could occur.
• If the software version is No.3600, never use the terminal function "BATRY" (Enable battery operation). This
function will not work. When the battery power is used in an Up/Down operation, the drive target may fall
due to insufficient lack in the worst case.
Otherwise, an accident could occur.

Safety precautions
v
• The cooling fin and braking resistor become very hot. Never touch them.
Otherwise, a burn could occur.
• The DC braking function of the inverter does not provide any holding mechanism.
Otherwise, an injury could occur.
• 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. Change the function code setting after making sure that safety is ensured.
• In digital input, the run and frequency command sources can be switched using "SS1, 2, 4, 8", "Hz2/Hz1",
"Hz/PID", "IVS", and "LE". When switching these signals, the motor may run suddenly or change speed
rapidly.
• 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.
Otherwise, an accident or injury could occur.
Maintenance and parts replacement
• 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 and parts replacement should be done by a specified person.
• Take off any metal objects (e.g., watch, ring) before work.
• Use insulated tools.
• Never alter anything.
Otherwise, an electric shock or injury could occur.
Disposal
• Dispose of the FRENIC-MEGA as an industrial waste.
Otherwise, an injury could occur.

How this manual is organized
vi
How this manual is organized
This manual contains Chapters 1 through 13, Appendices, and Index.
Chapter 1 BEFORE USE
This chapter describes the features, control system, and exterior, and precautions of the FRENIC-MEGA series
and the recommended configuration for the inverter and peripheral equipment.
Chapter 2 INSTALLATION AND WIRING
This chapter describes the installation method, notes on cabling, basic connection diagram, terminal
specifications, screw specifications, and recommended wire sizes.
Chapter 3 KEYPAD FUNCTIONS (OPERATING WITH THE KEYPAD)
This chapter describes the names and functions of the keypad and inverter operation using the keypad. The
inverter features three operation modes (Running, Programming and Alarm modes) which enable you to run and
stop the motor, monitor running status, set function code data, display running information required for
maintenance, and display alarm data.
Chapter 4 OPERATION
This chapter describes how to prepare for a test run as well as tuning and basic setting for each control method.
Chapter 5 FUNCTION CODES
This chapter contains overview tables of function codes available for the FRENIC-MEGA series of inverters,
function code index by purpose, and details of function codes.
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 routine inspection and regular inspection items, regular replacement parts, main circuit
electricity flow measurement, insulation test, and product warranty.
Chapter 8 BLOCK DIAGRAMS FOR CONTROL LOGIC
This chapter provides the main block diagrams for the control logic of the FRENIC-MEGA series of inverters.
Chapter 9 RUNNING THROUGH RS-485 COMMUNICATION
This chapter describes an overview of inverter operation through the RS-485 communications facility. Refer to the
RS-485 Communication User's Manual (MET271) for details.
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, HD/MD/LD drive mode, and motor drive control.

How this manual is organized
vii
Chapter 11 SELECTING PERIPHERAL EQUIPMENT
This chapter describes how to use a range of peripheral equipment and options, FRENIC-MEGA's configuration
with them, and requirements and precautions for selecting wires and crimp terminals.
Chapter 12 SPECIFICATIONS
This chapter describes specifications of the output ratings and external dimensions.
Chapter 13 COMPLIANCE WITH STANDARDS
This chapter describes how to conform to the international specifications such as UL, cUL, and European EMC
standards.
Appendices
Index

Icons
viii
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 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.

CONTENTS
ix
CONTENTS
Chapter 1 BEFORE USE
1.1 Features............................................................................................................1-1
1.2 Control System...............................................................................................1-15
1.2.1 Theory of inverter.................................................................................1-15
1.2.2 Motor drive controls..............................................................................1-16
1.3 Acceptance Inspection ...................................................................................1-17
1.4 External View..................................................................................................1-18
1.5 Recommended Configuration.........................................................................1-21
1.6 Precautions for Using Inverters......................................................................1-22
1.6.1 Operating environment.........................................................................1-22
1.6.2 Storage environment............................................................................1-23
[1] Temporary storage ..............................................................................1-23
[2] Long-term storage...............................................................................1-23
1.6.3 Precautions in introducing inverters.....................................................1-24
1.6.4 Precautions in running inverters...........................................................1-29
1.6.5 Precautions in using special motors.....................................................1-29
Chapter 2 INSTALLATION AND WIRING
2.1 Installation.........................................................................................................2-1
2.2 Wiring................................................................................................................2-3
2.2.1 Connection diagrams .............................................................................2-3
[1] Running a standard motor.....................................................................2-3
[2] Running a Fuji motor exclusively designed for vector control...............2-5
2.2.2 Removing and mounting the front cover and the wiring guide...............2-7
2.2.3 Wiring precautions..................................................................................2-8
2.2.4 Main circuit terminals............................................................................2-10
[1] Screw specifications and recommended wire size
(main circuit terminals)........................................................................2-10
[2] Terminal layout diagrams (main circuit terminals)...............................2-12
[3] Description of terminal functions (main circuit terminals)....................2-15
2.2.5 Control circuit terminals (common to all inverter types).......................2-19
[1] Screw specifications and recommended wire size
(control circuit terminals).....................................................................2-19
[2] Terminal layout diagrams (control circuit terminals)............................2-19
[3] Notes on control circuit wiring .............................................................2-20
[4] Terminal functions (control circuit).......................................................2-21
2.2.6 Switching connectors ...........................................................................2-32
2.2.7 Setting up the slide switches................................................................2-35
2.3 Attachment and Connection of Keypad..........................................................2-37
2.4 Protective Functions.......................................................................................2-38
Chapter 3 KEYPAD FUNCTIONS (OPERATING WITH THE KEYPAD)
3.1 LED Monitor, Keys and LED Indicators on the Keypad....................................3-1
3.2 Overview of Operation Modes..........................................................................3-4
3.3 Running Mode ..................................................................................................3-6
3.3.1 Monitoring the running status.................................................................3-6
3.3.2 Monitoring light alarms...........................................................................3-8
3.3.3 Setting up frequency and PID commands..............................................3-9
3.3.4 Running/stopping the motor.................................................................3-14

CONTENTS
x
3.3.5 Jogging operation.................................................................................3-14
3.3.6 Remote and local modes......................................................................3-15
3.3.7 External run/frequency command........................................................3-16
3.4 Programming Mode........................................................................................3-17
3.4.1 Setting up basic function codes quickly "Quick Setup"........................3-19
3.4.2 Setting up function codes Menu #1 "Data Setting" ..............................3-22
3.4.3 Checking changed function codes Menu #2 "Data Checking".............3-25
3.4.4 Monitoring the running status Menu #3 "Drive Monitoring"..................3-26
3.4.5 Checking I/O signal status Menu #4 "I/O Checking"............................3-30
3.4.6 Reading maintenance information Menu #5
"Maintenance Information"...................................................................3-35
3.4.7 Reading alarm information Menu #6 "Alarm Information"....................3-40
3.4.8 Copying data Menu #7 "Data Copying"................................................3-43
3.5 Alarm Mode ....................................................................................................3-47
3.5.1 Releasing the alarm and switching to Running mode..........................3-47
3.5.2 Displaying the alarm history.................................................................3-47
3.5.3 Displaying the status of inverter at the time of alarm...........................3-47
3.5.4 Switching to Programming mode.........................................................3-47
3.6 USB Connectivity............................................................................................3-49
Chapter 4 OPERATION
4.1 Test Run............................................................................................................4-1
4.1.1 Test run procedure .................................................................................4-1
4.1.2 Checking prior to powering on ...............................................................4-2
4.1.3 Powering on and checking.....................................................................4-2
4.1.4 Selecting an inverter drive mode (HD/MD/LD).......................................4-3
4.1.5 Selecting a motor drive control...............................................................4-4
4.1.6 Basic settings of function codes < 1 >....................................................4-8
4.1.7 Basic settings/tuning of function codes < 2 >.........................................4-9
4.1.8 Basic settings/tuning of function codes < 3 >.......................................4-12
4.1.9 Basic settings of function codes < 4 >..................................................4-17
4.1.10 Basic settings of function codes < 5 >..................................................4-18
4.1.11 Basic settings/tuning of function codes < 6 >.......................................4-19
4.1.12 Running the inverter for motor operation check...................................4-22
4.1.13 Preparation for production run .............................................................4-24
4.2 Special Operation ...........................................................................................4-25
4.2.1 Jogging operation.................................................................................4-25
4.2.2 Remote and local modes......................................................................4-26
4.2.3 External run/frequency command........................................................4-27
Chapter 5 FUNCTION CODES
5.1 Overview of Function Codes ............................................................................5-1
5.2 Function Code Tables.......................................................................................5-2
5.3 Code Index by Purpose..................................................................................5-37
5.3.1 Configuring the minimal requirements for the inverter to just run
the motor..............................................................................................5-37
5.3.2 Setting up the frequency ......................................................................5-37
[1] Frequency setting from the keypad.....................................................5-37
[2] Frequency setting by analog input......................................................5-37
[3] Other frequency settings.....................................................................5-38
5.3.3 Entering a run command......................................................................5-39
5.3.4 Starting/stopping the motor ..................................................................5-40
5.3.5 Specifying the acceleration/deceleration (time, mode, and pattern)....5-40

CONTENTS
xi
5.3.6 Adjusting the running performance......................................................5-41
5.3.7 Controlling the motor............................................................................5-42
[1] Motor drive control to be selected.......................................................5-42
[2] Motor parameters to be set up............................................................5-43
5.3.8 Setting up I/O terminals........................................................................5-44
5.3.9 Outputting monitored data....................................................................5-44
5.3.10 Keeping on running the motor..............................................................5-45
5.3.11 Detecting and outputting status signals ...............................................5-46
5.3.12 Running in various operation modes....................................................5-47
5.3.13 Setting up controls suited for individual applications ...........................5-49
[1] Droop control.......................................................................................5-49
[2] PID process control.............................................................................5-50
[3] PID dancer control...............................................................................5-52
5.3.14 Customizing the keypad.......................................................................5-54
5.3.15 Controlling the inverter via communications line..................................5-54
5.3.16 Using the customizable logic................................................................5-55
5.3.17 Activating the protective functions........................................................5-56
[1] Protection of machinery with limiters...................................................5-56
[2] Protection of motors............................................................................5-56
[3] Using other protective and safety functions........................................5-57
5.3.18 Maintenance.........................................................................................5-59
[1] Maintenance of inverters.....................................................................5-59
[2] Maintenance of machinery..................................................................5-60
5.4 Details of Function Codes ..............................................................................5-61
5.4.1 F codes (Fundamental functions).........................................................5-61
5.4.2 E codes (Terminal functions)..............................................................5-122
5.4.3 C codes (Control functions)................................................................5-166
5.4.4 P codes (Motor 1 parameters)............................................................5-175
5.4.5 H codes (High performance functions)...............................................5-181
5.4.6 A code (Motor 2 parameter) b code (Motor 3 parameter)
r code (Motor 4 parameter) ................................................................ 5-211
5.4.7 J codes (Application functions 1) .......................................................5-214
5.4.8 d codes (Application functions 2) .......................................................5-235
5.4.9 U codes (Application functions 3).......................................................5-249
5.4.10 y codes (Link functions)......................................................................5-272
Chapter 6 TROUBLESHOOTING
6.1 Protective Functions.........................................................................................6-1
6.2 Before Proceeding with Troubleshooting..........................................................6-3
6.3 If Neither an Alarm Code nor "Light Alarm" Indication ( l-al ) Appears
on the LED Monitor...........................................................................................6-4
6.3.1 Abnormal motor operation......................................................................6-4
[1] The motor does not rotate.....................................................................6-4
[2] The motor rotates, but the speed does not increase. ...........................6-6
[3] The motor runs in the opposite direction to the command....................6-7
[4] Speed fluctuation or current oscillation (e.g., hunting) occurs
during running at constant speed..........................................................6-7
[5] Grating sound is heard from the motor or the motor sound
fluctuates...............................................................................................6-8
[6] The motor does not accelerate or decelerate within the specified
time........................................................................................................6-8
[7] The motor does not restart even after the power recovers
from a momentary power failure. ..........................................................6-9
[8] The motor abnormally heats up. ...........................................................6-9
[9] The motor does not run as expected. ...................................................6-9

CONTENTS
xii
6.3.2 Problems with inverter settings ............................................................6-10
[1] Nothing appears on the LED monitor..................................................6-10
[2] The desired menu is not displayed. ....................................................6-10
[3] Data of function codes cannot be changed.........................................6-10
6.4 If an Alarm Code Appears on the LED Monitor .............................................. 6-11
6.4.1 0cn Instantaneous overcurrent......................................................... 6-11
6.4.2 ef Ground fault................................................................................. 6-11
6.4.3 0un Overvoltage...............................................................................6-12
6.4.4 lu Undervoltage ...............................................................................6-12
6.4.5 lin Input phase loss........................................................................6-13
6.4.6 0pl Output phase loss.....................................................................6-13
6.4.7 0h1 Heat sink overheat ....................................................................6-14
6.4.8 0h2 External alarm...........................................................................6-14
6.4.9 0h3 Inverter internal overheat..........................................................6-14
6.4.10 0h4 Motor protection (PTC/NTC thermistor)....................................6-15
6.4.11 dbh Braking resistor overheated......................................................6-15
6.4.12 fus Fuse blown................................................................................6-16
6.4.13 pbf Charger circuit fault...................................................................6-16
6.4.14 0ln Overload of motor 1 through 4..................................................6-16
6.4.15 0lu Inverter overload .......................................................................6-17
6.4.16 0s Overspeed...................................................................................6-18
6.4.17 pg PG wire break..............................................................................6-18
6.4.18 er1 Memory error.............................................................................6-18
6.4.19 er2 Keypad communications error ..................................................6-19
6.4.20 er3 CPU error..................................................................................6-19
6.4.21 er4 Option communications error....................................................6-19
6.4.22 er5 Option error...............................................................................6-19
6.4.23 er6 Operation protection..................................................................6-20
6.4.24 er7 Tuning error...............................................................................6-20
6.4.25 er8 RS-485 communications error (COM port 1)/
erp RS-485 communications error (COM port 2)............................6-21
6.4.26 erf Data saving error during undervoltage......................................6-21
6.4.27 erh Hardware error..........................................................................6-22
6.4.28 ere Speed mismatch or excessive speed deviation........................6-22
6.4.29 nrb NTC wire break error.................................................................6-23
6.4.30 err Mock alarm................................................................................6-23
6.4.31 cof PID feedback wire break...........................................................6-23
6.4.32 dba Braking transistor error..............................................................6-23
6.4.33 ero Positioning control error............................................................6-23
6.5 If the "Light Alarm" Indication ( l-al ) Appears on the LED Monitor..............6-24
6.6 If an Abnormal Pattern Appears on the LED Monitor while Neither
an Alarm Code nor "Light Alarm" Indication (
l-al ) is Displayed..................6-25
6.6.1 ---- (center bar) appears...............................................................6-25
6.6.2 ____ (under bar) appears................................................................6-25
6.6.3 c ] appears.................................................................................6-25
Chapter 7 MAINTENANCE AND INSPECTION
7.1 Daily Inspection ................................................................................................7-1
7.2 Periodic Inspection...........................................................................................7-2
7.3 List of Periodic Replacement Parts ..................................................................7-4
7.3.1 Judgment on service life.........................................................................7-4
7.4 Measurement of Electrical Amounts in Main Circuit.........................................7-8
7.5 Insulation Test...................................................................................................7-9
7.6 Inquiries about Product and Guarantee .........................................................7-10

CONTENTS
xiii
Chapter 8 BLOCK DIAGRAMS FOR CONTROL LOGIC
8.1 Symbols Used in Block Diagrams and their Meanings ....................................8-1
8.2 Drive Frequency Command Block....................................................................8-2
8.3 Drive Command Block......................................................................................8-4
8.4 Control Block ....................................................................................................8-6
8.4.1 V/f control...............................................................................................8-6
8.4.2 V/f control with speed sensor.................................................................8-8
8.4.3 Vector control with/without speed sensor.............................................8-10
8.5 PID Process Control Block.............................................................................8-12
8.6 PID Dancer Control Block...............................................................................8-14
8.7 FMA/FMP Output Selector .............................................................................8-16
Chapter 9 RUNNING THROUGH RS-485 COMMUNICATION
9.1 Overview on RS-485 Communication ..............................................................9-1
9.1.1 RS-485 common specifications..............................................................9-2
9.1.2 Terminal specifications for RS-485 communications .............................9-3
[1] RS-485 communications port 1 (for connecting the keypad)................9-3
[2] RS-485 communications port 2 (control circuit terminals) ....................9-3
9.1.3 Connection method................................................................................9-4
9.1.4 Communications support devices ..........................................................9-6
[1] Communications level converters .........................................................9-6
[2] Requirements for the cable (COM port 1: for RJ-45 connector)...........9-7
[3] Requirements for the cable (COM port 2: for RS-485 connector).........9-7
[4] Branch adapter for multi-drop ...............................................................9-7
9.1.5 Noise suppression..................................................................................9-7
9.2 Overview of FRENIC Loader............................................................................9-8
9.2.1 Specifications .........................................................................................9-8
9.2.2 Connection.............................................................................................9-9
9.2.3 Function overview ..................................................................................9-9
[1] Setting of function code.........................................................................9-9
[2] Multi-monitor........................................................................................9-10
[3] Running status monitor ....................................................................... 9-11
[4] Test-running.........................................................................................9-12
[5] Real-time trace....................................................................................9-13
[6] Historical trace.....................................................................................9-14
[7] USB port on the standard keypad.......................................................9-15
Chapter 10 SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES
10.1 Selecting Motors and Inverters.......................................................................10-1
10.1.1 Output torque characteristics ...............................................................10-1
10.1.2 Selection procedure .............................................................................10-4
10.1.3 Equations for selections.......................................................................10-7
[1] Load torque during constant speed running........................................10-7
[2] Acceleration and deceleration time calculation...................................10-9
[3] Heat energy calculation of braking resistor.......................................10-14
[4] Calculating the RMS rating of the motor...........................................10-15
10.2 Selecting a Braking Resistor ........................................................................10-16
10.2.1 Selection procedure ...........................................................................10-16
10.2.2 Notes on selection..............................................................................10-16
10.3 Selecting an Inverter Drive Mode (HD/MD/LD)............................................10-17
10.3.1 Precaution in making the selection ....................................................10-17
10.3.2 Guideline for selecting inverter drive mode and capacity ..................10-18
10.4 Selecting a Motor Drive Control....................................................................10-19

CONTENTS
xiv
10.4.1 Features of motor drive controls ........................................................10-19
10.4.2 Selecting a motor drive control by purpose........................................10-24
Chapter 11 SELECTING PERIPHERAL EQUIPMENT
11.1 Configuring the FRENIC-MEGA..................................................................... 11-1
11.2 Selecting Wires and Crimp Terminals............................................................. 11-2
11.2.1 Recommended wires............................................................................ 11-6
11.3 Peripheral Equipment................................................................................... 11-14
11.3.1 Molded case circuit breaker (MCCB),
residual-current-operated protective device (RCD)/
earth leakage circuit breaker (ELCB) and
magnetic contactor (MC).................................................................... 11-14
[1] Function overview ............................................................................. 11-14
[2] Connection example and criteria for selection of circuit breakers .... 11-16
11.3.2 Surge killer for L-load......................................................................... 11-21
11.3.3 Arrester............................................................................................... 11-22
11.3.4 Surge absorber................................................................................... 11-23
11.3.5 Filter capacitor for radio noise reduction............................................ 11-24
11.4 Option........................................................................................................... 11-25
11.4.1 Peripheral equipment options ............................................................ 11-25
[1] Braking resistors (DBRs) and braking units...................................... 11-25
[2] Power regenerative PWM converters, RHC series........................... 11-32
[3] DC reactor (DCR).............................................................................. 11-47
[4] AC reactor (ACR).............................................................................. 11-53
[5] Surge suppression unit (SSU)........................................................... 11-58
[6] Output circuit filter (OFL)................................................................... 11-59
[7] Zero-phase reactors for reducing radio noise (ACL)......................... 11-62
[8] IP40 kits (P40G1-) ...................................................................... 11-63
11.4.2 Options for operation and communication ......................................... 11-65
[1] External frequency command potentiometer (external volume) ....... 11-65
[2] Multi-function keypad (TP-G1-J1, TP-G1-C1)................................... 11-67
[3] Extension cable for remote operation ............................................... 11-68
[4] Inverter support loader...................................................................... 11-68
[5] PG interface card (OPC-G1-PG)....................................................... 11-69
[6] PG interface (5 V line driver) card (OPC-G1-PG2)........................... 11-72
[7] PG interface (5 V line driver x 2) card (OPC-G1-PG22)...................11-76
[8] Relay output interface card (OPC-G1-RY)........................................ 11-79
[9] Digital input interface card (OPC-G1-DI)........................................... 11-81
[10] Digital output interface card (OPC-G1-DO)....................................... 11-84
[11] Analog interface card (OPC-G1-AIO)................................................ 11-86
[12] T-Link communications card (OPC-G1-TL)....................................... 11-91
[13] SX-bus communications card (OPC-G1-SX).................................... 11-95
[14] CC-Link communications card (OPC-G1-CCL) ................................ 11-98
[15] PROFIBUS-DP communications card (OPC-G1-PDP)................... 11-100
[16] DeviceNet communications card (OPC-G1-DEV)........................... 11-104
[17] CANopen communications card (OPC-G1-COP) ........................... 11-107
11.4.3 Option cards for operation and communication................................11-110
[1] About option cards for operation and communication......................11-110
11.4.4 Meter options.....................................................................................11-111
[1] Frequency meters ............................................................................11-111

CONTENTS
xv
Chapter 12 SPECIFICATIONS
12.1 Standard Model 1 (Basic Type) ......................................................................12-1
12.1.1 Three-phase 200 V class series...........................................................12-1
12.1.2 Three-phase 400 V class series...........................................................12-2
12.2 Standard Model 2 (EMC Filter Built-in Type)..................................................12-5
12.2.1 Three-phase 200 V class series...........................................................12-5
12.2.2 Three-phase 400 V class series...........................................................12-6
12.3 Standard Model 3 (DC Reactor Built-in Type)................................................12-9
12.3.1 Three-phase 200 V class series...........................................................12-9
12.3.2 Three-phase 400 V class series.........................................................12-10
12.4 Common Specifications................................................................................ 12-11
12.5 External Dimensions.....................................................................................12-18
12.5.1 Basic type and EMC filter built-in type ...............................................12-18
12.5.2 DC reactor built-in type.......................................................................12-27
12.5.3 Keypad ...............................................................................................12-28
Chapter 13 COMPLIANCE WITH STANDARDS
13.1 Compliance with UL Standards and Canadian Standards (cUL certification) .......13-1
13.1.1 General.................................................................................................13-1
13.1.2 Conformity with UL standards and Canadian standards
(cUL certification)..................................................................................13-1
13.2 Conformity with European Standards.............................................................13-6
13.3 Conformity with EMC Directives in Europe ....................................................13-6
13.3.1 General.................................................................................................13-6
13.3.2 Recommended installation method......................................................13-7
13.3.3 Leakage current from the EMC filter built-in type.................................13-9
13.4 Regulations on Harmonics in Europe...........................................................13-10
13.4.1 General...............................................................................................13-10
13.4.2 Compliance ........................................................................................13-10
13.5 Conformity with Low Voltage Directive in Europe......................................... 13-11
13.5.1 General............................................................................................... 13-11
13.5.2 Note.................................................................................................... 13-11
13.6 (End) Radio Waves Act (South Korea).........................................................13-16
Appendices
App. A Advantageous Use of Inverters (Notes on Electrical Noise) ............................. 1
A.1 Effect of inverters on other devices........................................................... 1
A.2 Noise ......................................................................................................... 2
A.3 Noise prevention ....................................................................................... 4
App. 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
B.2 Compliance to the harmonic suppression for customers receiving
high voltage or special high voltage........................................................ 13
App. 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............................................... 18
C.4 Regarding existing equipment................................................................. 19
App. D Inverter Generating Loss................................................................................. 20
App. E Conversion from SI Units................................................................................. 21
App. F Allowable Current of Insulated Wires .............................................................. 23

CONTENTS
xvi
App. G Replacement Information ................................................................................ 25
G.1 External dimensions comparison tables.................................................. 25
G.2 Terminal arrangements and symbols ...................................................... 29
G.3 Function code..........................................................................................36
App. H Precautions for Inverter Connection
(When Using the Power Regenerative PWM Converters (RHC Series))........ 75
Index

Chapter 1
BEFORE USE
This chapter describes the check items before the use of the inverter.
Contents
1.1 Features....................................................................................................................................1-1
1.2 Control System........................................................................................................................1-15
1.2.1 Theory of inverter.............................................................................................................1-15
1.2.2 Motor drive controls..........................................................................................................1-16
1.3 Acceptance Inspection............................................................................................................1-17
1.4 External View ..........................................................................................................................1-18
1.5 Recommended Configuration .................................................................................................1-21
1.6 Precautions for Using Inverters...............................................................................................1-22
1.6.1 Operating environment.....................................................................................................1-22
1.6.2 Storage environment........................................................................................................1-23
[1] Temporary storage .....................................................................................................1-23
[2] Long-term storage......................................................................................................1-23
1.6.3 Precautions in introducing inverters.................................................................................1-24
1.6.4 Precautions in running inverters.......................................................................................1-29
1.6.5 Precautions in using special motors.................................................................................1-29