Fuji Electric frenic mini series User manual

FRENIC Mini ユーザーズマニュアルレターサイズ C■M■Y■K■
USER'S MANUAL
MEHT530
Information in this manual is subject to change without notice. Printed in Japan 2007-7 (G07/G07) CM 05 FIS
47520 Westinghouse DriveFremont, CA 94538, U.S.A.
Phone: [phone] Fax: [phone]
Fuji Electric FA Components & Systems Co., Ltd.
Fuji Electric Corp. of America

Compact Inverter
User's Manual

Copyright © 2002-2007 Fuji Electric FA Components & Systems Co., Ltd.
All rights reserved.
No part of this publication may be reproduced or copied without prior written permission from Fuji Electric FA
Components & Systems 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.

i
Preface
This manual provides all the information on the FRENIC-Mini 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.
Listed below are the other materials related to the use of the FRENIC-Mini. Read them in conjunction with this
manual as necessary.
• FRENIC-Mini Instruction Manual
• RS-485 Communication User's Manual
• Catalog
• Application Guide
• RS-485 Communications Card Installation Manual
• Rail Mounting Base Installation Manual
• Mounting Adapter Installation Manual
• FRENIC Loader Instruction Manual
• Remote Keypad Instruction Manual
• Built-in Braking Resistor Installation Manual
The materials are subject to change without notice. Be sure to obtain the latest editions for use.
Documents related to Fuji inverters
Catalogs
FRENIC5000G11S/P11S
FRENIC-Eco
FRENIC5000VG7S
User's Manuals and Technical Information
FRENIC5000G11S/P11S Technical Information
FRENIC-Eco User's Manual
FRENIC5000VG7S Series User's Manual

ii
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.
This product is not designed for use in appliances and machinery on which lives depend. Consult your Fuji
Electric representative before considering the FRENIC-Mini 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.

iii

Precautions for Use
Driving a 460V
general-purpose
motor
When driving a 460V general-purpose motor with an inverter using
extremely long wires, damage to the insulation of the motor may occur. Use
an output circuit filter (OFL) if necessary after checking with the motor
manufacturer. Fuji motors do not require the use of output circuit filters
because of their good insulation.
Torque
characteristics
and temperature
rise
When the inverter is used to run a general-purpose motor, the temperature
of the motor becomes higher than when it is operated using a commercial
power supply. In the low-speed range, the cooling effect will be weakened,
so decrease the output torque of the motor. If constant torque is required in
the low-speed range, use a Fuji inverter motor or a motor equipped with an
externally powered ventilating fan.
Vibration
When an inverter-driven motor is mounted to a machine, resonance may be
caused by the natural frequencies of the machine system.
Note that operation of a 2-pole motor at 60 Hz or higher may cause
abnormal vibration.
* The use of a rubber coupling or vibration dampening rubber is
recommended.
* Use the inverter's jump frequency control feature to skip the resonance
frequency zone(s).
In running
general-
purpose
motors
Noise
When an inverter is used with a general-purpose motor, the motor noise
level is higher than that with a commercial power supply. To reduce noise,
raise carrier frequency of the inverter. Operation at 60 Hz or higher can also
result in higher noise level.
High-speed
motors
If the set frequency is set to 120 Hz or more to drive a high-speed motor,
test-run the combination of the inverter and motor beforehand to check for
safe operation.
Explosion-proof
motors
When driving an explosion-proof motor with an inverter, use a combination
of a motor and an inverter that has been approved in advance.
Submersible
motors and pumps
These motors have a larger rated current than general-purpose motors.
Select an inverter whose rated output current is greater than that of the
motor.
These motors differ from general-purpose motors in thermal characteristics.
Set a low value in the thermal time constant of the motor when setting the
electronic thermal overload protection.
In running
special
motors
Brake motors
For motors equipped with parallel-connected brakes, their braking power
must be supplied from the primary circuit. If the brake power is connected
to the inverter's power output circuit by mistake, the brake will not work.
Do not use inverters for driving motors equipped with series-connected
brakes.

iv
Geared motors
If the power transmission mechanism uses an oil-lubricated gearbox or
speed changer/reducer, then continuous motor operation at low speed may
cause poor lubrication. Avoid such operation.
Synchronous
motors
It is necessary to take special measures suitable for this motor type. Contact
your Fuji Electric representative for details.
In running
special
motors
Single-phase
motors
Single-phase motors are not suitable for inverter-driven variable speed
operation. Use three-phase motors.
* Even a single-phase inverter provides three-phase output, so use a
three-phase motor.
Environ-
mental
conditions
Installation
location
Use the inverter within the ambient temperature range from -10 to +50qC
(+14 to 122qF ).
The heat sink and braking resistor of the inverter may become hot under
certain operating conditions, so install the inverter on nonflammable
material such as metal.
Ensure that the installation location meets the environmental conditions
specified in Chapter 8, Section 8.5 "Operating Environment and Storage
Environment."
Installing an
MCCB or
RCD/GFCI
Install a recommended molded case circuit breaker (MCCB) or
residual-current-operated protective device (RCD)/ground-fault circuit
interrupter (GFCI) (with overcurrent protection) in the primary circuit of
the inverter to protect the wiring. Ensure that the circuit breaker capacity is
equivalent to or lower than the recommended capacity.
Installing an MC
in the secondary
circuit
If a magnetic contactor (MC) is mounted in the inverter's secondary circuit
for switching the motor to commercial power or for any other purpose,
ensure that both the inverter and the motor are completely stopped before
you turn the MC on or off.
Do not connect a magnet contactor united with a surge killer to the inverter's
secondary circuit.
Installing an MC
in the primary
circuit
Do not turn the magnetic contactor (MC) in the primary circuit on or off
more than once an hour as an inverter failure may result.
If frequent starts or stops are required during motor operation, use
FWD/REV signals or the RUN/STOP key.
Combina-
tion with
peripheral
devices
Protecting the
motor
The electronic thermal overload protection function of the inverter can
protect the motor. The operation level and the motor type (general-purpose
motor, inverter motor) should be set. For high-speed motors or
water-cooled motors, set a small value for the thermal time constant and
protect the motor.
If you connect the motor thermal relay to the motor with a long wire, a
high-frequency current may flow into the wiring stray capacitance. This
may cause the relay to trip at a current lower than the set value for the
thermal relay. If this happens, lower the carrier frequency or use the output
circuit filter (OFL).

v
Discontinuance of
power-factor
correcting
capacitor
Do not mount power-factor correcting capacitors in the inverter’s primary
circuit. (Use the DC reactor to improve the inverter power factor.) Do not
use power-factor correcting capacitors in the inverter output circuit. An
overcurrent trip will occur, disabling motor operation.
Discontinuance of
surge killer Do not connect a surge killer to the inverter's secondary circuit.
Reducing noise Use of a filter and shielded wires is typically recommended to satisfy EMC
directives.
Measures against
surge currents
If an overvoltage trip occurs while the inverter is stopped or operated under
a light load, it is assumed that the surge current is generated by open/close
of the phase-advancing capacitor in the power system.
* Connect a DC reactor to the inverter.
Combina-
tion with
peripheral
devices
Megger test
When checking the insulation resistance of the inverter, use a 500 V megger
and follow the instructions contained in the FRENIC-Mini Instruction
Manual, Chapter 7, Section 7.4 "Insulation Test."
Control circuit
wiring length
When using remote control, limit the wiring length between the inverter and
operator box to 65.6 ft (20 m) or less and use twisted pair or shielded cable.
Wiring length
between inverter
and motor
If long wiring is used between the inverter and the motor, the inverter will
overheat or trip as a result of overcurrent (high-frequency current flowing
into the stray capacitance) in the wires connected to the phases. Ensure that
the wiring is shorter than 164 ft (50 m). If this length must be exceeded,
lower the carrier frequency or mount an output circuit filter (OFL).
Wiring size Select wires with a sufficient capacity by referring to the current value or
recommended wire size.
Wiring type Do not use one multicore cable in order to connect several inverters with
motors.
Wiring
Grounding Securely ground the inverter using the grounding terminal.
Driving
general-purpose
motor
Select an inverter according to the applicable motor ratings listed in the
standard specifications table for the inverter.
When high starting torque is required or quick acceleration or deceleration
is required, select an inverter with a capacity one size greater than the
standard.
Selecting
inverter
capacity
Driving special
motors
Select an inverter that meets the following condition:
Inverter rated current > Motor rated current
Transpor-
tation and
storage
When transporting or storing inverters, follow the procedures and select locations that meet the
environmental conditions listed in Chapter 1, Section 1.3 "Transportation" and Section 1.4
"Storage Environment."


vi
How this manual is organized
This manual contains chapters 1 through 9, appendices and glossary.
Part 1 General Information
Chapter 1 INTRODUCTION TO FRENIC-Mini
This chapter describes the features and control system of the FRENIC-Mini series, and the recommended
configuration for the inverter and peripheral equipment.
Chapter 2 PARTS NAMES AND FUNCTIONS
This chapter contains external views of the FRENIC-Mini series and an overview of terminal blocks, including a
description of the LED display and keys on the keypad.
Chapter 3 OPERATION USING THE KEYPAD
This chapter describes 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.
Part 2 Driving the Motor
Chapter 4 BLOCK DIAGRAMS FOR CONTROL LOGIC
This chapter describes the main block diagrams for the control logic of the FRENIC-Mini series of inverters.
Chapter 5 RUNNING THROUGH RS-485 COMMUNICATION (OPTION)
This chapter describes an overview of inverter operation through the RS-485 communications facility. Refer to
the RS-485 Communication User's Manual for details.
Part 3 Peripheral Equipment and Options
Chapter 6 SELECTING PERIPHERAL EQUIPMENT
This chapter describes how to use a range of peripheral equipment and options, FRENIC-Mini's configuration
with them, and requirements and precautions for selecting wires and crimp terminals.
Part 4 Selecting Optimal Inverter Model
Chapter 7 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.

vii
Part 5 Specifications
Chapter 8 SPECIFICATIONS
This chapter describes specifications of the output ratings, control system, and terminal functions for the
FRENIC-Mini series of inverters. It also provides descriptions of the operating and storage environment, external
dimensions, examples of basic connection diagrams, and details of the protective functions.
Chapter 9 FUNCTION CODES
This chapter contains overview lists of seven groups of function codes available for the FRENIC-Mini series of
inverters and details of each function code.
Appendices
App.A Advantageous Use of Inverters (Notes on electrical noise)
App.B Japanese Guideline for Suppressing Harmonics by Customers Receiving High Voltage or Special High
Voltage
App.C Effect on Insulation of General-purpose Motors Driven with 460 V Class Inverters
App.D Inverter Generating Loss
App.E Conversion from SI Units
App.F Allowable Current of Insulated Wires
App.G Replacement Information
Glossary
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 o
r
operations.
This icon indicates a reference to more detailed information.

viii
CONTENTS
Part 1 General Information
Chapter 1 INTRODUCTION TO FRENIC-Mini
1.1 Features..................................................................................................................................................... 1-1
1.2 Control System ......................................................................................................................................... 1-8
1.3 Recommended Configuration ................................................................................................................... 1-9
Chapter 2 PARTS NAMES AND FUNCTIONS
2.1 External View and Allocation of Terminal Blocks.................................................................................... 2-1
2.2 LED Monitor, Potentiometer and Keys on the Keypad ............................................................................ 2-2
Chapter 3 OPERATION USING THE KEYPAD
3.1 Overview of Operation Modes ................................................................................................................. 3-1
3.2 Running Mode .......................................................................................................................................... 3-3
3.2.1 Run/stop the motor.............................................................................................................................. 3-3
3.2.2 Set up the set frequency and others..................................................................................................... 3-3
3.2.3 Monitor the running status .................................................................................................................. 3-5
3.2.4 Jog (inch) the motor ............................................................................................................................ 3-7
3.3 Programming Mode .................................................................................................................................. 3-8
3.3.1 Setting the function codes--"Data Setting".......................................................................................... 3-9
3.3.2 Checking changed function codes--"Data Checking" ....................................................................... 3-13
3.3.3 Monitoring the running status--"Drive Monitoring" ......................................................................... 3-14
3.3.4 Checking I/O signal status--"I/O Checking" ..................................................................................... 3-17
3.3.5 Reading maintenance information--"Maintenance Information" ...................................................... 3-21
3.3.6 Reading alarm information--"Alarm Information"............................................................................ 3-22
3.4 Alarm Mode............................................................................................................................................ 3-26
3.4.1 Releasing the alarm and transferring the inverter to Running mode................................................. 3-26
3.4.2 Displaying the alarm history ............................................................................................................. 3-26
3.4.3 Displaying the running information when an alarm occurs .............................................................. 3-27
3.4.4 Transferring to Programming mode .................................................................................................. 3-27
Part 2 Driving the Motor
Chapter 4 BLOCK DIAGRAMS FOR CONTROL LOGIC
4.1 Symbols Used in the Block Diagrams and their Meanings.......................................................................4-1
4.2 Drive Frequency Command Generator..................................................................................................... 4-2
4.3 Drive Command Generator....................................................................................................................... 4-4
4.4 Terminal Command Decoders .................................................................................................................. 4-6
4.5 Digital Output Selector ........................................................................................................................... 4-10
4.6 Analog Output (FMA) Selector .............................................................................................................. 4-12
4.7 Drive Command Controller .................................................................................................................... 4-14
4.8 PID Frequency Command Generator...................................................................................................... 4-16

ix
Chapter 5 RUNNING THROUGH RS-485 COMMUNICATION (OPTION)
5.1 Overview on RS-485 Communication...................................................................................................... 5-1
5.1.1 Common specifications....................................................................................................................... 5-2
5.1.2 Connector specifications ..................................................................................................................... 5-3
5.1.3 Connection .......................................................................................................................................... 5-3
Part 3 Peripheral Equipment and Options
Chapter 6 SELECTING PERIPHERAL EQUIPMENT
6.1 Configuring the FRENIC-Mini................................................................................................................. 6-1
6.2 Selecting Wires and Crimp Terminals....................................................................................................... 6-2
6.2.1 Recommended wires ........................................................................................................................... 6-4
6.2.2 Crimp terminals................................................................................................................................... 6-6
6.3 Peripheral Equipment ............................................................................................................................... 6-7
6.4 Selecting Options.................................................................................................................................... 6-13
6.4.1 Peripheral equipment options............................................................................................................ 6-13
6.4.2 Options for operation and communications ...................................................................................... 6-21
6.4.3 Extended installation kit options ....................................................................................................... 6-24
6.4.4 Meter options .................................................................................................................................... 6-27
Part 4 Selecting Optimal Inverter Model
Chapter 7 SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES
7.1 Selecting Motors and Inverters ................................................................................................................. 7-1
7.1.1 Motor output torque characteristics..................................................................................................... 7-1
7.1.2 Selection procedure............................................................................................................................. 7-4
7.1.3 Equations for selections ...................................................................................................................... 7-7
7.1.3.1 Load torque during constant speed running ................................................................................ 7-7
7.1.3.2 Acceleration and deceleration time calculation........................................................................... 7-8
7.1.3.3 Heat energy calculation of braking resistor............................................................................... 7-11
7.1.3.4 Calculating the RMS rating of the motor .................................................................................. 7-12
7.2 Selecting a Braking Resistor................................................................................................................... 7-13
7.2.1 Selection procedure........................................................................................................................... 7-13
7.2.2 Notes on selection ............................................................................................................................. 7-13

x
Part 5 Specifications
Chapter 8 SPECIFICATIONS
8.1 Standard Models ....................................................................................................................................... 8-1
8.1.1 Three-phase 230 V .............................................................................................................................. 8-1
8.1.2 Three-phase 460 V .............................................................................................................................. 8-2
8.1.3 Single-phase 230 V ............................................................................................................................. 8-3
8.2 Models Available on Order ....................................................................................................................... 8-4
8.2.1 EMC filter built-in type....................................................................................................................... 8-4
8.2.1.1 Three-phase 230 V ...................................................................................................................... 8-4
8.2.1.2 Three-phase 460 V ...................................................................................................................... 8-5
8.2.1.3 Single-phase 230 V ..................................................................................................................... 8-6
8.2.2 Braking resistor built-in type............................................................................................................... 8-7
8.2.2.1 Three-phase 230 V ...................................................................................................................... 8-7
8.2.2.2 Three-phase 460 V ...................................................................................................................... 8-8
8.3 Common Specifications............................................................................................................................ 8-9
8.4 Terminal Specifications .......................................................................................................................... 8-11
8.4.1 Terminal functions ............................................................................................................................ 8-11
8.4.2 Terminal block arrangement.............................................................................................................. 8-23
8.4.3 Terminal arrangement diagram and screw specifications.................................................................. 8-24
8.4.3.1 Main circuit terminals ............................................................................................................... 8-24
8.4.3.2 Control circuit terminal ............................................................................................................. 8-25
8.5 Operating Environment and Storage Environment ................................................................................. 8-26
8.5.1 Operating environment...................................................................................................................... 8-26
8.5.2 Storage environment ......................................................................................................................... 8-27
8.5.2.1 Temporary storage..................................................................................................................... 8-27
8.5.2.2 Long-term storage ..................................................................................................................... 8-27
8.6 External Dimensions............................................................................................................................... 8-28
8.6.1 Standard models and models available on order (braking resistor built-in type) .............................. 8-28
8.6.2 Models available on order (EMC filter built-in type)........................................................................ 8-30
8.7 Connection Diagrams ............................................................................................................................. 8-32
8.7.1 Keypad operation .............................................................................................................................. 8-32
8.7.2 Operation by external signal inputs................................................................................................... 8-33
8.8 Details of Protective Functions............................................................................................................... 8-34
Chapter 9 FUNCTION CODES
9.1 Function Code Tables ............................................................................................................................... 9-1
9.2 Details of Function Codes....................................................................................................................... 9-12
9.2.1 F codes (Fundamental functions) ...................................................................................................... 9-12
9.2.2 E codes (Extension terminal functions)............................................................................................. 9-33
9.2.3 C codes (Control functions of frequency) ......................................................................................... 9-46
9.2.4 P codes (Motor parameters) .............................................................................................................. 9-49
9.2.5 H codes (High performance functions) ............................................................................................. 9-51
9.2.6 J codes (Application functions)......................................................................................................... 9-64
9.2.7 y codes (Link functions).................................................................................................................... 9-70

xi
Appendices
App.A Advantageous Use of Inverters (Notes on electrical noise)................................................................... A-1
A.1 Effect of inverters on other devices.................................................................................................... A-1
A.2 Noise .................................................................................................................................................. A-2
A.3 Noise prevention ................................................................................................................................ A-4
App.B Japanese Guideline for Suppressing Harmonics by Customers Receiving High Voltage or
Special High Voltage ........................................................................................................................... A-12
B.1 Application to general-purpose inverters ......................................................................................... A-12
B.2 Compliance to the harmonic suppression for customers receiving high voltage or
special high voltage.......................................................................................................................... A-13
App.C Effect on Insulation of General-purpose Motors Driven with 460 V Class Inverters.......................... A-17
C.1 Generating mechanism of surge voltages......................................................................................... A-17
C.2 Effect of surge voltages.................................................................................................................... A-18
C.3 Countermeasures against surge voltages.......................................................................................... A-18
C.4 Regarding existing equipment.......................................................................................................... A-19
App.D Inverter Generating Loss ..................................................................................................................... A-20
App.E Conversion from SI Units.................................................................................................................... A-21
App.F Allowable Current of Insulated Wires ................................................................................................. A-23
App.G Replacement Information .................................................................................................................... A-25
G.1 External dimensions comparison tables ........................................................................................... A-25
G.2 Terminal arrangements and symbols ................................................................................................ A-29
G.3 Function codes ................................................................................................................................. A-31
Glossary

Part 1 General Information
Chapter 1 INTRODUCTION TO FRENIC-Mini
Chapter 2 PARTS NAMES AND FUNCTIONS
Chapter 3 OPERATION USING THE KEYPAD

Chapter 1
INTRODUCTION TO FRENIC-Mini
This chapter describes the features and control system of the FRENIC-Mini series, and the recommended
configuration for the inverter and peripheral equipment.
Contents
1.1 Features....................................................................................................................................................... 1-1
1.2 Control System............................................................................................................................................ 1-8
1.3 Recommended Configuration ..................................................................................................................... 1-9

1.1 Features
1-1
Chap. 1 INTRODUCTION TO FRENIC-Mini
1.1 Features
Optimum performance for traversing conveyors
• High starting torque, at 150% or more
Equipped with Fuji's original simplified torque-vector control system and the automatic torque boost
function, these inverters ensure consistent and powerful operation (when automatic torque boost and slip
compensation control are ON and start frequency is set at 5 Hz or more).
Figure 1.1 Torque Characteristics Data
(Automatic torque boost: ON)
Figure 1.2 Example of Output Torque Characteristics
• Braking resistor connectable to the inverter
FRENIC-Mini series of inverters features a built-in braking transistor (for inverters of 1/2 HP or larger),
which makes it possible for an optional braking resistor to be connected to increase the regenerative
braking ability for conveyance and transportation machinery that requires strong braking power. For
inverters of 2 HP or larger, it is also possible to select a model that incorporates a built-in braking resistor.
Refer to Chapter 8, Section 8.2.2 "Braking resistor built-in type" for details.
• Trip-free operation
The remarkably improved current limiting function (stall prevention) ensures trip-free operation even for
impact loads.
Figure 1.3 Example of Response for Impact Load Torque
• Stable operation even for a step load
The slip compensation function ensures stable operation even when the motor load fluctuates (step load).
Figure 1.4 Example of Response for Step Load Torque (Refer to the note in Figure 1.2 for the test configuration.)