Fuji Electric OPC-G1-CCL Operating Manual

/ Instruction Manual

CC-Link Communications Card

"OPC-G1-CCL"

Fuji Electric Co., Ltd. INR-SI47-1328d-JE

English Version

Preface

Thank you very much for purchasing our CC-Link Communications Card "OPC-G1-CCL." This manual has been prepared to help you connect your FRENIC-MEGA to a CC-Link master (Mitsubishi

Electric PLC, etc.) via CC-Link. Mounting this communications card on your FRENIC-MEGA allows you to connect the FRENIC-MEGA to a

CC-Link master and control it as a slave using run commands, speed commands, and access to inverter's function codes.

The communications card can be connected to the A-port only, out of three option connection ports (A-, B-, and C-ports) provided on the FRENIC-MEGA.

The communications card has the following features:

• CC-Link Version: Complies with CC-Link versions 1.10 and 2.00

• Applicable Profile: Inverter (1 station occupied)

• Monitoring the status of the FRENIC-MEGA (running status, frequency, output torque, output current, output voltage, etc.)

• Reading and writing from/to function codes applicable to the FRENIC-MEGA

Logo mark:

The communications card is a CC-Link version 2.00 compliant remote device unit and supports the following:

- Extended cyclic transmission

- Easing restrictions on inter-station cable length This instruction manual does not contain inverter handling instructions. Read through this instruction manual in

conjunction with the FRENIC-MEGA Instruction Manual and be familiar with proper handling and operation of this product. Improper handling might result in incorrect operation, a short life, or even a failure of this product.

Keep this manual in a safe place.

Related Publications Listed below are the other materials related to the use of the CC-Link Communications Card "OPC-G1-CCL."

Read them in conjunction with this manual as necessary.

• RS-485 Communication User's Manual

• FRENIC-MEGA Instruction Manual The materials are subject to change without notice. Be sure to obtain the latest editions for use.

• Read through this instruction manual and be familiar with the CC-Link communications card before

proceeding with installation, connections (wiring), operation, or maintenance and inspection.

• Improper handling might result in incorrect operation, a short life, or even a failure of this product as

well as the motor.

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

is discarded.

Safety precautions

Read this manual thoroughly before proceeding with installation, connections (wiring), operation, or maintenance and inspection. Ensure you have sound knowledge of the device and familiarize yourself with all safety information and precautions before proceeding to operate the inverter.

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

Failure to heed the information indicated by this symbol may lead to dangerous conditions, possibly resulting in death or serious bodily injuries.

Failure to heed the information indicated by this symbol may lead to dangerous conditions, possibly resulting in minor or light bodily injuries and/or substantial property damage.

Failure to heed the information contained under the CAUTION title can also result in serious consequences. These safety precautions are of utmost importance and must be observed at all times.

Installation and wiring

• Before starting installation and wiring, turn OFF the power and wait at least five minutes for inverters with a capacity of 22 kW or below, or at least ten minutes for inverters with a capacity of 30 kW or above. Make sure that the LED monitor and charging lamp are turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped to the safe level (+25 VDC or below).

• Qualified electricians should carry out wiring.

Otherwise, electric shock could occur.

• Do not use the products that are damaged or lacking parts.

Doing so could cause a fire, accident, or injury.

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

Otherwise, a fire or an accident might result.

• Incorrect handling in installation/removal jobs could cause a failure.

A failure might result.

• Noise may be emitted from the inverter, motor and wires. Implement appropriate measure to prevent the nearby sensors and devices from malfunctioning due to such noise.

Otherwise, an accident could occur.

Operation

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

Otherwise electric shock could occur.

• Do not operate switches with wet hands.

Doing so could cause electric shock.

• If you configure the function codes wrongly or without completely understanding FRENIC-MEGA Instruction Manual and the FRENIC-MEGA User's Manual, the motor may rotate with a torque or at a speed not permitted for the machine. Confirm and adjust the setting of the function codes before running the inverter.

Otherwise, an accident could occur.

Maintenance and inspection, and parts replacement

• Before proceeding to the maintenance/inspection jobs, turn OFF the power and wait at least five minutes for inverters with a capacity of 22 kW or below, or at least ten minutes for inverters with a capacity of 30 kW or above. Make sure that the LED monitor and charging lamp are turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped to the safe level (+25 VDC or below).

Otherwise, 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, electric shock or injuries could occur.

Disposal

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

Otherwise injuries could occur.

Others

• Never modify the communications card.

Doing so could cause electric shock or injuries.

Icons

The following icons are used throughout this manual.

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

This icon indicates information that can prove handy when performing certain settings or operations.

This icon indicates a reference to more detailed information.

Table of Contents

Preface ..................................................................... 1

Safety precautions ............................................................ 2

Chapter 1 BEFORE USE ................................................... 5

1.1 Acceptance Inspection .......................................... 5

1.2 Applicable Inverters ............................................... 5

Chapter 2 NAMES AND FUNCTIONS ............................... 6

2.1 External Appearance ............................................. 6

2.2 Terminating Resistor Switch (SW1) ....................... 6

2.3 LED Status Indicators ............................................ 7

Chapter 3 INSTALLATION AND REMOVAL OF THE

CC-Link COMMUNICATIONS CARD ................ 8

3.1 Installing the Communications Card ...................... 8

3.2 Removing the Communications Card .................... 9

Chapter 4 WIRING AND CABLING .................................. 10

4.1 Basic Connection Diagram .................................. 10

4.2 Wiring for CC-Link Terminal Block ........................ 11

4.3 Wiring to Inverter ................................................. 12

Chapter 5 CONFIGURING INVERTER'S FUNCTION

CODES FOR CC-Link COMMUNICATION ..... 13

Chapter 6 SETTING-UP PROCEDURE ........................... 14

Chapter 7 LIST OF I/O SIGNALS ..................................... 15

7.1 Remote I/O Signals ............................................. 15

7.2 Remote Registers ................................................ 17

7.3 List of Monitor Item Codes ................................... 21

7.4 Command Codes and Response Codes ............. 23

Chapter 8 ERROR PROCESSING FOR CC-Link

NETWORK BREAKS ....................................... 25

Chapter 9 LIST OF INVERTER ALARM CODES ............. 26

Chapter 10 APPLICATION PROGRAM EXAMPLES ........ 27

10.1 System Configuration ........................................... 27

10.2 Network Parameter Settings ................................ 27

10.3 Relationship between Master Station Device

and Remote I/O and Remote Register ................. 28

10.4 CC-Link Startup Program ..................................... 29

10.5 Program Example Using the Inverter Running

Status Read ......................................................... 29

10.6 Program Example for Changing the Operation

Mode .................................................................... 30

10.7 Program Example for Specifying Run Command . 30

10.8 Program Example for Monitoring the Output

Frequency ............................................................ 31

10.9 Program Example for Reading from the

Inverter's Function Code Data ............................. 31

10.10 Program Example for Writing to Inverter's

Function Code Data ............................................. 32

10.11 Program Example for Setting up the Reference

Frequency ............................................................ 33

10.12 Program Example for Reading out Alarm Codes . 34

10.13 Program Example for Resetting a Inverter Trip .... 34

Chapter 11 TROUBLESHOOTING ................................... 35

Chapter 12 SPECIFICATIONS ......................................... 36

12.1 General Specifications ......................................... 36

12.2 CC-Link Specifications ......................................... 36

Chapter 1 BEFORE USE

1.1 Acceptance Inspection

Unpack the package and check the following: (1) A communications card, two screws (M3 8), and the CC-Link Communications Card Instruction Manual

(this manual) are contained in the package. (2) The communications card is not damaged during transportation--no defective parts, dents or warps. (3) The model name "OPC-G1-CCL" is printed on the communications card. (See Figure 1.1.)

If you suspect the product is not working properly or if you have any questions about your product, contact the shop where you bought the product or your local Fuji branch office.

Screw hole (left)

Model name

Release knob

Connector CN1

(Front) (Back)

Positioning cutout

Figure 1.1 Names of Parts on CC-Link Communications Card

Screw hole (right)

1.2 Applicable Inverters

The CC-Link communications card is applicable to the following inverters and ROM version.

Table 1.1 Applicable Inverters and ROM Version

Series Inverter type Applicable motor rating ROM version

FRENIC-MEGA FRN G1 - All capacities 0500 or later

* The boxes replace alphanumeric letters depending on the nominal applied motor, enclosure, power supply voltage, etc.

To check the inverter's ROM version, use Menu #5 "Maintenance Information" on the keypad. (Refer to the FRENIC-MEGA Instruction Manual, Chapter 3, Section 3.4.6 "Reading maintenance information.")

Table 1.2 Checking the Inverter ROM Version

Display on LED Monitor Item Description

Inverter's ROM version Shows the inverter's ROM version as a 4-digit code.

Chapter 2 NAMES AND FUNCTIONS

2.1 External Appearance

The external appearance and the components of the CC-Link communications card are shown in Figure 2.1 and Table 2.1, respectively.

TERM1

CN1 (on the back)

SW1

Figure 2.1 External View and Component Names

Table 2.1 Components on the CC-Link Communications Card

LED status indicators

Component Description

TERM1 CC-Link terminal block (3.5 mm pitch)

CN1 Connector for joint with inverter

SW1

Terminating resistor switch (For details, see Section 2.2.) (ON: Insertion of terminating resistor, OFF: No insertion)

LED status indicators RD, SD, L.ERR, RUN, and L.RUN (For details, see Section 2.3.)

2.2 Terminating Resistor Switch (SW1)

The CC-Link communications network requires insertion of line terminating resistors at its both ends. When this communications card is mounted on the inverter at either end of the network, turn this switch ON to insert the terminating resistor.

ON OFF

OFF: No insertion of terminating resistor ON: Insertion of terminating resistor

Figure 2.2 Terminating Resistor Switch Settings

2.3 LED Status Indicators

This communications card has five LED status indicators shown below. They indicate the operation status of the communications card as listed in Table 2.2.

Figure 2.3 LED Status Indicators

Table 2.2 LED Status Indicators and Operation Status

LED States

L.RUN RUN L.ERR SD RD

Normally communicating.

Normally communicating. But sometimes a CRC error occurs due to electrical noise.

Received data contains a CRC error, so the communications card cannot respond.

Data destined for this station does not come. Responding to polling. But refresh data received

contains a CRC error. The inverter trips with alarm displayed. *1

Data destined for this station contains a CRC error. The inverter trips with alarm displayed. *1

Station address incorrectly specified. Data destined for this station cannot be received due

to electrical noise. Transmission speed (Baud rate) and/or station

address out of the allowable range.

Operation Status

Transmission speed (Baud rate) or station address changed during CC-Link communication.

The communications card cannot receive data due to

: ON, : OFF, : Blinking (It may seem to be ON depending on the current transmission speed.)

*1 Alarm occurs when a communications error is detected after a normal communications link has been

established once.

It is possible to change the occurrence conditions with inverter's function codes. For details, refer to

Chapter 8 "ERROR PROCESSING FOR CC-Link NETWORK BREAKS."

a network break, etc. The inverter trips with alarm displayed. *1

The master station is compliant with CC-Link version

1.xx and this slave station, with CC-Link version 2.xx. Or the inverter's function code o30 is set to "5 to 255."

The inverter trips with alarm displayed. Communications error between the communications

card and the inverter. The inverter trips with alarm displayed.

Communications card error. The inverter trips with alarm displayed.

Chapter 3 INSTALLATION AND REMOVAL OF THE CC-Link COMMUNICATIONS

CARD

Before starting installation and wiring, turn OFF the power and wait at least five minutes for inverters with a capacity of 22 kW or below, or at least ten minutes for inverters with a capacity of 30 kW or above. Make sure that the LED monitor and charging lamp are turned OFF. Further, make sure, using a multimeter or a similar instrument, that the DC link bus voltage between the terminals P(+) and N(-) has dropped to the safe level (+25 VDC or below).

Otherwise, electric shock could occur.

• Do not use the products that are damaged or lacking parts.

Doing so could cause a fire, accident, or injury.

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

Otherwise, a fire or an accident might result.

• Incorrect handling in installation/removal jobs could cause a failure.

A failure might result.

Before mounting the communications card, perform the wiring for the main circuit terminals and control circuit terminals.

3.1 Installing the Communications Card

(1) Remove the front cover from the inverter and expose the control printed circuit board (control PCB). As

shown in Figure 3.1, the communications card can be connected to the A-port only, out of three option connection ports (A-, B-, and C-ports) on the control PCB.

To remove the front cover, refer to the FRENIC-MEGA Instruction Manual, Chapter 2, Section 2.3. For inverters with a capacity of 30 kW or above, open also the keypad enclosure.

(2) Insert connector CN1 on the back of the communications card (Figure 1.1) into the A-port (CN4) on the

inverter's control PCB. Then secure the communications card with the two screws that come with the communications card. (Figure 3.3)

Check that the positioning cutout (shown in Figure 1.1) is fitted on the tab ( in Figure 3.2) and connector CN1 is fully inserted ( in Figure 3.2). Figure 3.3 shows the communications card correctly mounted.

(3) Perform wiring on the communications card.

Refer to Chapter 4 "WIRING AND CABLING."

(4) Put the front cover back into place.

To put back the front cover, refer to the FRENIC-MEGA Instruction Manual, Chapter 2, Section 2.3. For inverters with a capacity of 30 kW or above, close also the keypad enclosure.

Figure 3.1 In the case of 0.4 kW

Fit the positioning cutout of the communications card over the tab on the inverter to determine the mounting position.

Insert connector CN1 on the communications card into the A-port on the inverter's control PCB.

Note: Be sure to follow the order of and .

Inserting CN1 first may lead to insufficient insertion, resulting in a contact failure.

Figure 3.2 Mounting the Communications Card

(Release knob)

Figure 3.3 Mounting Completed

3.2 Removing the Communications Card

Remove the two screws that secure the communications card and pull the release knob (shown above) to take the communications card out of the inverter.

Chapter 4 WIRING AND CABLING

• Qualified electricians should carry out wiring.

Otherwise, an electric shock could occur.

• In general, the covers of the control signal wires are not specifically designed to withstand a high voltage (i.e., reinforced insulation is not applied). Therefore, if a control signal wire comes into direct contact with a live conductor of the main circuit, the insulation of the cover might break down, which would expose the signal wire to a high voltage of the main circuit. Make sure that the control signal wires will not come into contact with live conductors of the main circuit.

Failure to observe this precaution could cause an electric shock or fire.

Noise may be emitted from the inverter, motor and wires. Take appropriate measures to prevent the nearby sensors and devices from malfunctioning due to such noise.

An accident could occur.

4.1 Basic Connection Diagram

To CC-Link network

CC-Link cable

L1/R L2/S L3/T

Blue

White

Yellow

CC-Link terminal block

FRENIC-MEGA

FG SLD

Terminating

resistor switch

DB DG

U V

Motor

OPC-G1-CCL

Figure 4.1 Basic Connection Diagram

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