Fuji Electric FRENIC-MEGA Bedienungsanleitung

Instruction Manual

High Performance, Multifunction Inverter

This product is designed to drive a three-phase induction motor. Read through this manual to become familiar with proper

handling and correct use.

Improper handling might result in incorrect operation, short life cycle, or failure of this product as well as the motor.

Deliver this manual to the end user of this product. Keep this manual in a safe place until this product is discarded.

For instructions on how to use an optional device, refer to the instruction and installation manuals for that optional device.

Fuji Electric Co., Ltd.

Fuji Electric Corp. of America INR-SI47-1457a-E

No part of this publication may be reproduced or copied without prior written permission from

Fuji Electric Corp. of America.

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.

Preface

This product is designedto drivea three-phase induction motor. Read through thismanual to become familiar with proper handling

and correct use.

Improper handling might result in incorrect operation, shorter life cycle, or failure of this product as well as the motor.

Have this manual delivered to the end user of this product. Keep this manual in a safe place until this product is discarded.

Listed below are the other materials related to the use of the FRENIC-MEGA. Read them in conjunction with this manual as

necessary.

• FRENIC-MEGA User's Manual

• RS-485 Communication User's Manual

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

Safety precautions

Read this manual thoroughly before proceeding with installation, connections (wiring), operation, or maintenance and inspection.

Ensure you have sound knowledge of the device and familiarize yourself with all safety information and precautions before

proceeding to operate the inverter.

Safety precautions are classified into the following two categories in this manual.

Failure to heed the information indicated by this symbol may lead to dangerous conditions,

possibly resulting in death or serious bodily injuries.

Failure to heed the information indicated by this symbol may lead to dangerous conditions,

possibly resulting in minor or light bodily injuries and/or substantial property damage.

Failure to heed the information contained under the CAUTION title can also result in serious consequences. These safety

precautions are of utmost importance and must be observed at all times.

Application

• The FRENIC-MEGA is designed to drive a three-phase induction motor. Do not use it for single-phase motors or for other

purposes.

Fire or an accident could occur.

• The FRENIC-MEGA may not be used for a life-support system or other purposes directly related to the human safety.

• Though the FRENIC-MEGA is manufactured under strict quality control, install safety devices for applications where

serious accidents or property damages are foreseen in relation to the failure of it.

An accident could occur.

Installation

• Install the inverter on a base made of metal or other non-flammable material.

Otherwise, a fire could occur.

• Do not place flammable object nearby.

Doing so could cause fire.

• Inverters with a capacity of 50 HPor above, whose protective structure is IP00, involve a possibility that a human body may

touch the live conductors of the main circuit terminal block. Inverters to which an optional DC reactor is connected also

involve the same. Install such inverters in an inaccessible place.

Otherwise, electric shock or injuries could occur.

• Do not support the inverter by its front cover during transportation.

Doing so could cause a drop of the inverter and injuries.

• Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the inverter or from

accumulating on the heat sink.

• When changing the positions of the top and bottom mounting bases, use only the specified screws.

Otherwise, a fire or an accident might result.

• Do not install or operate an inverter that is damaged or lacking parts.

Doing so could cause fire, an accident or injuries.

Wiring

• If no zero-phase current (earth leakage current) detective device such as a ground-fault relay is installed in the upstream

power supply line in order to avoid the entire power supply system's shutdown undesirable to factory operation, install a

residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) individually to inverters to break

the individual inverter power supply lines only.

Otherwise, a fire could occur.

• When wiring the inverter to the power source, insert a recommended molded case circuit breaker (MCCB) or

residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) (with overcurrent protection) in the

path of each pair of power lines to inverters. Use the recommended devices within the recommended current capacity.

• Use wires of the specified size.

• Tighten terminals with specified torque.

Otherwise, a fire could occur.

• When there is more than one combination of an inverter and motor, do not use a multiconductor cable for the purpose of

running the leads together.

• Do not connect a surge killer to the inverter's output (secondary) circuit.

Doing so could cause a fire.

• Be sure to connect an optional DC reactor (DCR) when the capacity of the power supply transformer exceeds 500 kVA and

is 10 times or more the inverter rated capacity.

Otherwise, a fire could occur.

• Ground the inverter in compliance with the national or local electric code.

• Be sure to ground the inverter's grounding terminals G.

Otherwise, an electric shock or a fire could occur.

• Qualified electricians should carry out wiring.

• Be sure to perform wiring after turning the power OFF.

Otherwise, an electric shock could occur.

• Be sure to perform wiring after installing the inverter unit.

Otherwise, an electric shock or injuries could occur.

• Ensure that the number of input phases and the rated voltage of the product match the number of phases and the voltage of

the AC power supply to which the product is to be connected.

Otherwise, a fire or an accident could occur.

• Do not connect the power supply wires to output terminals (U, V, and W).

• When connecting a DC braking resistor (DBR), never connect it to terminals other than terminals P(+) and DB.

Doing so could cause fire or an accident.

• In general, the insulation 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 may break down, which would expose the signal wire to the high voltage of the main circuit. Make

sure that the control signal wires will not come into contact with live conductors of the main circuit.

Doing so could cause an accident or an electric shock.

iii

• Before changing the switches or touching the control circuit terminal symbol plate, turn OFF the power and wait at least

five minutes forinverters of 40 HPor below, or at least ten minutes for inverters of 50 HPor above. Make sure that the

LED monitor and charging lamp are turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC

link bus voltage between the terminals P(+) and N(-) has dropped to the safe level (+25 VDC or below).

Otherwise, an electric shock could occur.

• The inverter, motor and wiring generate electric noise. This may cause the malfunction of nearby sensors and devices. To

prevent malfunctioning, implement noise control measures.

Otherwise an accident could occur.

Operation

• Be sure to mount the front cover before turning the power ON. Do not remove the cover when the inverter power is ON.

Otherwise, an electric shock could occur.

• Do not operate switches with wet hands.

Doing so could cause electric shock.

• If the auto-reset function has been selected, the inverter may automatically restart and drive the motor depending on the

cause of tripping. Design the machinery or equipment so that human safety is ensured at the time of restarting.

Otherwise, an accident could occur.

• If the stall prevention function (current limiter), automatic deceleration (anti-regenerative control), or overload prevention

control has been selected, the inverter may operate with acceleration/deceleration or frequency different from the

commanded ones. Design the machine so that safety is ensured even in such cases.

• If any of the protective functions have been activated, first remove the cause. Then, after checking that the all run commands

are set to OFF, release the alarm. If the alarm is released while any run commands are set to ON, the inverter may supply the

power to the motor, running the motor.

Otherwise, an accident could occur.

• If you enable the "Restart mode after momentary power failure" (Function code F14 = 3 to 5), then the inverter

automatically restarts running the motor when the power is recovered.

Design the machinery or equipment so that human safety is ensured after restarting.

• If the user configures the function codes wrongly without completely understanding this Instruction Manual and the

FRENIC-MEGAUser's Manual, the motor may rotate with a torque or at a speed not permitted for the machine.

An accident or injuries could occur.

• Even if the inverter has interrupted power to the motor, if the voltage is applied to the main circuit input terminals L1/R,

L2/S and L3/T, voltage may be output to inverter output terminals U, V, and W.

• Even if the run command is set to OFF, voltage is output to inverter output terminals U, V, and W if the servo-lock command

is ON.

• Even if the motor is stopped due to DC braking or preliminary excitation, voltage is output to inverter output terminals U, V,

and W.

An electric shock may occur.

• The inverter can easily accept high-speed operation. When changing the speed setting, carefully check the specifications of

motors or equipment beforehand.

Otherwise, injuries could occur.

• Do not touch the heat sink and braking resistor because they become very hot.

Doing so could cause burns.

• The DC brake function of the inverter does not provide any holding mechanism.

Injuries could occur.

• Ensure safety before modifying the function code settings.

Run commands (e.g., "Run forward" FWD), stop commands (e.g., "Coast to a stop" BX), and frequency change commands

can be assigned to digital input terminals. Depending upon the assignment states of those terminals, modifying the function

code setting may cause a sudden motor start or an abrupt change in speed.

• When the inverter is controlled with the digital input signals, switching run or frequency command sources with the related

terminal commands (e.g., SS1, SS2, SS4, SS8, Hz2/Hz1, Hz/PID, IVS, and LE) may cause a sudden motor start oran abrupt

change in speed.

• Ensure safety before modifying customizable logic related function code settings (U codes and related function codes) or

turning ON the "Cancel customizable logic" terminal command CLC. Depending upon the settings, such modification or

cancellation of the customizable logic may change the operation sequence to cause a sudden motor start or an unexpected

motor operation.

An accident or injuries could occur.

Maintenance and inspection, and parts replacement

• Before proceeding to the maintenance/inspection jobs, turn OFF the power and wait at least five minutes for inverters

of 40 HPor below, or at least ten minutes for inverters of 50 HPor 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.

• Never modify the inverter.

Doing so could cause an electric shock or injuries.

Disposal

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

Otherwise injuries could occur.

GENERAL PRECAUTIONS

Drawings in this manual may be illustrated without covers or safety shields for explanation of detail parts. Restore the covers and

shields in the original state and observe the description in the manual before starting operation.

Icons

The following icons are used throughout this manual.

This icon indicates information which, if not heeded, can result in the inverter not operating to full efficiency, as well as

information concerning incorrect operations and settings which can result 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.

Conformity to the Low Voltage Directive in the EU

If installed according to the guidelines given below, inverters marked with CE are considered as compliant with the Low Voltage

Directive 2006/95/EC.

Compliance with European Standards

Adjustable speed electrical power drive systems (PDS).

Part 5-1: Safety requirements. Electrical, thermal and energy. EN61800-5-1: 2007

1. The ground terminal G should always be connected to the ground. Do not use only a residual-current-operated protective

device (RCD)/earth leakage circuit breaker (ELCB)* as the sole method of electric shock protection. Be sure to use ground

wires whose size is greater than power supply lines.

*With overcurrent protection.

2. To prevent the risk of hazardous accidents that could be caused by damage of the inverter, install the specified fuses in the

supply side (primary side) according to the following tables.

- Breaking capacity: Min. 10 kA

- Rated voltage: Min. 500 V

Power

supply

volta

e Inverter type Fuse rating

(A)

230 V

FRNF50G1S-2U 10 (IEC60269-2)

FRN001G1S-2U 15 (IEC60269-2)

FRN002G1S-2U 20 (IEC60269-2)

FRN003G1S-2U 30 (IEC60269-2)

FRN005G1S-2U 40 (IEC60269-2)

FRN007G1-2U 125 (IEC60269-4)

FRN010G1-2U

FRN015G1-2U 160 (IEC60269-4)

FRN020G1-2U

FRN025G1-2U 200 (IEC60269-4)

FRN030G1-2U 250 (IEC60269-4)

FRN040G1-2U

FRN050G1-2U 350 (IEC60269-4)

FRN060G1-2U 400 (IEC60269-4)

FRN075G1-2U 450 (IEC60269-4)

FRN100G1-2U

500 (IEC60269-4)

FRN125G1S-2U

FRN150G1S-2U

Note: A box () in these tables replaces S or H depending on the enclosure.

Fuses

Note: When using the inverter on single-phase input power also, use fuses suitable

for the inverter type as specified on this page.

Power

supply

volta

eInverter type Fuse rating

(A)

460 V

FRNF50G1S-4U 3 (IEC60269-2)

FRN001G1S-4U 6 (IEC60269-2)

FRN002G1S-4U 10 (IEC60269-2)

FRN003G1S-4U 15 (IEC60269-2)

FRN005G1S-4U 20 (IEC60269-2)

FRN007G1-4U

80 (IEC60269-4)

FRN010G1-4U

FRN015G1-4U

FRN020G1-4U 125 (IEC60269-4)

FRN025G1-4U

FRN030G1-4U 160 (IEC60269-4)

FRN040G1-4U

FRN050G1-4U 250 (IEC60269-4)

FRN060G1-4U 315 (IEC60269-4)

FRN075G1-4U

FRN100G1-4U

350 (IEC60269-4)

FRN125G1S-4U

FRN150G1S-4U

FRN200G1S-4U 400 (IEC60269-4)

FRN250G1S-4U 450 (IEC60269-4)

FRN300G1S-4U 500 (IEC60269-4)

FRN350G1S-4U 550 (IEC60269-4)

FRN450G1S-4U 630 (IEC60269-4)

FRN500G1S-4U 900 (IEC60269-4)

FRN600G1S-4U

FRN700G1S-4U 1250

(IEC60269-4)

FRN800G1S-4U

FRN900G1S-4U 2000

(IEC60269-4)

FRN1000G1S-4U

Conformity to the Low Voltage Directive in the EU (Continued)

3. When used with the inverter, a molded case circuit breaker (MCCB), residual-current-operated protective device

(RCD)/earth leakage circuit breaker (ELCB) or magnetic contactor (MC) should conform to the EN or IEC standards.

4. When you use a residual-current-operated protective device (RCD)/earth leakage circuit breaker (ELCB) for protection from

electric shock in direct or indirect contact power lines or nodes, be sure to install type B of RCD/ELCB on the input (primary)

of the inverter if the power supply is three-phase 200/400 V.

5. The inverter should be used in an environment that does not exceed Pollution Degree 2 requirements. If the environment

conforms to Pollution Degree 3 or 4, install the inverter in an enclosure of IP54 or higher.

6. Install the inverter, AC or DC reactor, input or output filter in an enclosure with minimum degree of protection of IP2X (Top

surface of enclosure shall be minimum IP4X when it can be easily accessed), to prevent human body from touching directly

to live parts of these equipment.

7. Do not connect any copper wire directly to grounding terminals. Use crimp terminals with tin or equivalent platingto connect

them.

8. Use wires listed in IEC60364-5-52.

Power supply voltage

Nominal applied

motor

(HP) Inverter type

HD / LD mode

MCCB or

RCD/ELCB *1

Rated current

Recommended wire size (mm2)

Main circuit

Control circuit

Aux. control power

supply [R0, T0]

Aux. fan power

supply [R1, T1]

Main power

input *2

[L1/R, L2/S, L3/T]

Inverter’s

grounding *3

[G]

Inverter outputs

[U, V, W] *2

DC reactor

[P1, P(+)] *2

Braking resistor

[P(+), DB] *2

Three-

phase Single-

phase W/

DCR W/o

DCR W/

DCR W/o

DCR

230 V

0.5 0.25 FRNF50G1S-2U

HD/LD

5 5

1 1 1 1

0.65

0.82

1 0.5 FRN001G1S-2U 10

2 1 FRN002G1S-2U 10 15

2.5

3 1.5 FRN003G1S-2U 20 1.5

FRN005G1S-2U 20 30 2.5 4 2.5 2.5

7.5 FRN007G1-2U 30 50 4 6 4 4

FRN010G1-2U HD

10 5 LD 40 75 6 10 6 6

FRN015G1-2U HD 10

15 7.5 LD 50 100 10 16 16

FRN020G1-2U HD

20 10

LD 75 125 16 25 16 25

FRN025G1-2U HD

25 LD

100 150 25 35 25 35

FRN030G1-2U HD

1.5

30 15 LD 175 35 50 35

FRN040G1-2U HD

40 20 LD 150 200 50 70 50 70

FRN050G1-2U HD 2.5

50 25 LD 175 250 70 95 70 95

FRN060G1-2U HD 4

2.5

LD 200 300 95 70×2 95 50×2

FRN075G1-2U HD 6

75 LD 250 350 50×2 95×2 70×2 70×2

FRN100G1-2U HD 10

100 LD 350

95×2

95×2 95×2

40 FRN125G1S-2U HD

125 LD 400 120×2 120×2 120×2

FRN150G1S-2U HD

150 50 LD 500 150×2 150×2 150×2

Note: A box () in the above table replaces S or H depending on the enclosure.

*1 The frame size and model of the MCCB or RCD/ELCB (with overcurrent protection) will vary, depending on the power transformer capacity. Refer

to the related technical documentation for details.

*2 The recommended wire size for main circuits is for the 70°C (158°F) 600 V PVC wires used at a surrounding temperature of 40°C (104°F).

*3 Grounding terminal can accept one wire only.

vii

Conformity to the Low Voltage Directive in the EU (Continued)

Power supply voltage

Nominal applied

motor

(HP) Inverter type

HD/MD/LD mode

MCCB or

RCD/ELCB *1

Rated current

Recommended wire size (mm2)

Main circuit

Control circuit

Aux. control power

supply [R0, T0]

Aux. fan power

supply [R1, T1]

Main power

input *2

[L1/R, L2/S, L3/T]

Inverter’s

grounding *3

[G]

Inverter outputs

[U, V, W] *2

DC reactor

[P1, P(+)] *2

Braking resistor

[P(+), DB] *2

Three-

phase Single-

phase W/

DCR W/o

DCR W/

DCR W/o

DCR

460 V

0.5 0.25 FRNF50G1S-4U

HD/LD

5 5

1 1 1

0.65

0.82

1 0.5 FRN001G1S-4U

2 1 FRN002G1S-4U 10

2.5

3 1.5 FRN003G1S-4U 10 15

FRN005G1S-4U 20 1.5

7.5 FRN007G1-4U 15 30 2.5 1.5 1.5

FRN010G1-4U HD

10 LD 20 40 1.5 4 2.5 2.5

5 FRN015G1-4U HD

15 LD 30 50 4 6 4 4

7.5 FRN020G1-4U HD

20 LD

40 60 6 10 6 6

10 FRN025G1-4U HD

25 LD 75 16 10 10

FRN030G1-4U HD

30 15 LD 50 100 10 16

FRN040G1-4U HD

40 20 LD 75 125 16 25 16 25

FRN050G1-4U HD

50 25 LD

100 25 35 25

FRN060G1-4U HD

1.5

60 30

LD 150 50 35 35

FRN075G1-4U HD

75 LD 125 200 35 70 50 70

FRN100G1-4U HD 2.5

100 40 LD 175

70 95

FRN125G1S-4U HD 4

2.5

125 50 LD 200 95 95 120

FRN150G1S-4U HD

150 MD/LD 250 50×2 70×2 150

60 FRN200G1S-4U HD

200 MD/LD 300 70×2 70×2

FRN250G1S-4U HD

250 75 MD/LD 350 185 240 300

FRN300G1S-4U HD

300 100

MD/LD

500 300 300 120×2

FRN350G1S-4U HD

350 MD/LD 150×2 150×2

FRN450G1S-4U HD

Note: A box () in the above table replaces S or H depending on the enclosure.

*1 The frame size and model of the MCCB or RCD/ELCB (with overcurrent protection) will vary, depending on the power transformer capacity. Refer

to the related technical documentation for details.

*2 The recommended wire size for main circuits is for the 70°C (158°F) 600 V PVC wires used at a surrounding temperature of 40°C (104°F).

*3 Grounding terminal can accept one wire only.

viii

Conformity to the Low Voltage Directive in the EU (Continued)

Power supply voltage

Nominal applied

motor

(HP) Inverter type

HD/MD/LD mode

MCCB or

RCD/ELCB *1

Rated current

Recommended wire size (mm2)

Main circuit

Control circuit

Aux. control power

supply [R0, T0]

Aux. fan power

supply [R1, T1]

Main power

input *2

[L1/R, L2/S, L3/T]

Inverter’s

grounding *3

[G]

Inverter outputs

[U, V, W] *2

DC reactor

[P1, P(+)] *2

Braking resistor

[P(+), DB] *2

Three-

phase Single-

phase W/

DCR W/o

DCR W/

DCR W/o

DCR

460 V

350 -

FRN450G1S-4U MD 600

185×2

185×2 185×2

- 0.65

0.82 2.5 2.5

450 125 LD

240×

240×2 240×2

400 FRN500G1S-4U HD

450 - MD

800 300×2

150 FRN600G1S-4U HD

500 FRN500G1S-4U LD 300×2 300×2- FRN600G1S-4U MD

150 FRN700G1S-4U HD

600 200 FRN600G1S-4U LD

1200

240×3 240×3 300×3- FRN700G1S-4U MD

200 FRN800G1S-4U HD

700 FRN700G1S-4U LD

300×3 300×3 240×4

- FRN800G1S-4U MD

800 250 LD 240×4

300×4

FRN900G1S-4U HD

900 300 LD 1400 300×4 300×4

FRN1000G1S-4U HD

1000 400 LD 1600

*1 The frame size and model of the MCCB or RCD/ELCB (with overcurrent protection) will vary, depending on the power transformer capacity. Refer

to the related technical documentation for details.

*2 The recommended wire size for main circuits is for the 70°C (158°F) 600 V PVC wires used at a surrounding temperature of 40°C (104°F).

*3 Grounding terminal can accept one wire only.

9. When you use an inverter at an altitude of more than 6600 ft (2000 m), you should apply basic insulation for the control

circuits of the inverter. The inverter cannot be used at altitudes of more than 9800 ft (3000 m).

10. The inverter has been tested with IEC61800-5-1 2007 5.2.3.6.3 Short-circuit Current Test under the following conditions.

Short-circuit current in the supply: 10 kA

Maximum 240 V for 200 V series with 40 HP or below

Maximum 230 V for 200 V series with 50 HP or above

Maximum 480 V for 400 V series

11. Connect the inverter to a power system which has a grounded neutral-point. In case of a non-grounded system (ex.

Delta-Delta), the control interface of the inverter is basic insulation, thus do not connect SELV circuit from external

controller directly. See Basic connection diagram (2.3.4).

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