Xerox SMALLTALK-72 User Manual

Compact Inverter

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User's Manual

Copyright © 2002-2007 Fuji Electric FA Components & Systems Co., Ltd.

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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.

Preface

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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

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Safety precautions

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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.

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Precautions for Use

Driving a 460V
general-purpose
motor

Torque
characteristics
and temperature
rise

In running
general­purpose
motors

Vibration

Noise

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.

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.

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).

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.

In running
special
motors

High-speed
motors

Explosion-proof
motors

Submersible
motors and pumps

Brake 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.

When driving an explosion-proof motor with an inverter, use a combination
of a motor and an inverter that has been approved in advance.

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.

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.

iii

Geared motors

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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.

In running
special
motors

Environ­mental
conditions

Combina­tion with
peripheral
devices

Synchronous
motors

Single-phase
motors

Installation
location

Installing an
MCCB or
RCD/GFCI

Installing an MC
in the secondary
circuit

Installing an MC
in the primary
circuit

It is necessary to take special measures suitable for this motor type. Contact
your Fuji Electric representative for details.

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.

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."

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.

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.

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.

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).

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Discontinuance of

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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.

Combina­tion with
peripheral
devices

Wiring

Discontinuance of
surge killer

Reducing noise

Measures against
surge currents

Megger test

Control circuit
wiring length

Wiring length
between inverter
and motor

Wiring size

Wiring type

Do not connect a surge killer to the inverter's secondary circuit.

Use of a filter and shielded wires is typically recommended to satisfy EMC
directives.

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.

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."

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.

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).

Select wires with a sufficient capacity by referring to the current value or
recommended wire size.

Do not use one multicore cable in order to connect several inverters with
motors.

Selecting
inverter
capacity

Transpor­tation and
storage

Grounding Securely ground the inverter using the grounding terminal.

Select an inverter according to the applicable motor ratings listed in the

Driving
general-purpose
motor

Driving special
motors

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."

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.

Select an inverter that meets the following condition:
Inverter rated current > Motor rated current

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v

How this manual is organized

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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.

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Part 5 Specifications

r

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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
operations.



This icon indicates a reference to more detailed information.

vii

CONTENTS

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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

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Chapter 5 RUNNING THROUGH RS-485 COMMUNICATION (OPTION)

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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

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Part 5 Specifications

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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

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Appendices

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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

xi

Part 1 General Information

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Chapter 1 INTRODUCTION TO FRENIC-Mini

Chapter 2 PARTS NAMES AND FUNCTIONS

Chapter 3 OPERATION USING THE KEYPAD

Chapter 1

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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

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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).

1.1 Features

Chap. 1 INTRODUCTION TO FRENIC-Mini

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.)

1-1

• Reduced motor instability at low speed

Fuji's unique control method improves voltage control performance and reduces motor instability at low
speed to about a half or under (at 1 Hz) compared with that of conventional inverters.

Refer to Chapter 4, Section 4.7 "Drive Command Controller" for details.



Figure 1.5 Example of Instability Characteristics

Default functions for fans and pumps

• Automatic energy-saving function provided as standard

To minimize the total loss (motor loss plus inverter loss), rather than just the motor loss as in the
predecessor models, FRENIC-Mini saves even more power when used with fans or pumps.

Refer to Chapter 4, Section 4.7 "Drive Command Controller" for details.



* Energy savings vary depending on the motor characteristics.

Figure 1.6 Example of Energy Savings

• PID control function

Permits motor operation while controlling temperature, pressure, or flow rate without using an external
device such as a temperature regulator.

Refer to Chapter 4, Section 4.8 "PID Frequency Command Generator" for details.



• Cooling fan ON/OFF control function

The inverter's cooling fan can be turned off while the fan or pump is stopped for noise reduction and
energy savings.

The ideal functions to serve a multiplicity of needs for small-capacity inverters

• Compatible with a wide range of frequency settings

You can select the optimum frequency setting method that matches your machine or equipment via the
keypad (
speed settings (0 to 7 steps) or via RS-485 communications. (Refer to Chapter 4, Section 4.2 "Drive
Frequency Command Generator" and Chapter 9, Section 9.2.1 "F codes" for details.)

/

keys or potentiometer), analog input (4 to 20 mA, 0 to 10 V, 0 to 5 V, 1 to 5 V), multistep

1-2

• A transistor output is provided

This enables an overload early warning, lifetime forecast or other information signals to be output during
operation.

Refer to function code E20 in Chapter 9, Section 9.2.2 "E codes (Extension terminal functions)."



• High output frequency - up to 400 Hz

The inverter can be used with equipment such as centrifugal separators that require a high motor speed. In
this case, you need to check whether the machine operation in combination with the motor is compatible or
not.

• Two points can be set for a non-linear V/f pattern.

The addition of an extra point (total: 2 points) for the non-linear V/f pattern, which can be set as desired,
improves the FRENIC-Mini's drive capability, because the V/f pattern can be adjusted to match a wider
application area.

Refer to Chapter 4, Section 4.7 "Drive Command Controller" for details.



Compact size

• Side-by-side mounting

More than one FRENIC-Mini inverter can be mounted side-by-side without any gap inside your system
control panel, thereby reducing the amount of space required for installation. (Ambient temperature: 40°C
(104°F) or lower)

1.1 Features

Chap. 1 INTRODUCTION TO FRENIC-Mini

(Example: Inverters of 3-phase 230 V, 1 HP or less)

• External dimensions compatible with Fuji FVR-C11S series

1-3

• RS-485 communications card (option) can be installed internally

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This card can be installed inside the inverter's body without changing the dimensions. RS-485
communication is available as option.

Refer to Chapter 5, "RUNNING THROUGH RS-485 COMMUNICATION (OPTION)."



RS-485 communications
card (option)

(Example: Inverters of 3-phase 230 V, 1 HP or less)

• Models with built-in braking resistor are available on order

Inverters of 2 HP or over are available in a braking resistor built-in type. Requiring no installation or
wiring of an external braking resistor reduces the total mounting space.

Refer to Chapter 8, Section 8.2.2 "Braking resistor built-in type."



(Example: Inverters of 3-phase 230V, 2 HP)

Simplified operation and wiring

• Frequency setting potentiometer is standard equipment

The frequency can be adjusted easily by hand.

1-4

1.1 Features

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• Easy-to-remove/replace terminal block covers (for control circuit and main circuit)

• LED monitor on the keypad displaying all types of data

You can access and monitor all types of inverter's data and information including output frequency, set
frequency, load shaft speed, output current, output voltage, alarm history, input power etc. using built-in
keypad with LED.

Refer to Chapter 3, "OPERATION USING THE KEYPAD."



Chap. 1 INTRODUCTION TO FRENIC-Mini

• Menu mode accessible from the keypad

You can easily access the menu mode including "Data setting," "Data checking," "Drive monitoring," "I/O
checking," "Maintenance information," and "Alarm information."

Refer to Chapter 3, "OPERATION USING THE KEYPAD."



1-5

Maintenance

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FRENIC-Mini series features the following facilities useful for maintenance.

Refer to Chapter 3, Section 3.3.5 "Reading Maintenance Information" and the FRENIC-Mini



Instruction Manual, Chapter 7 "MAINTENANCE AND INSPECTION" for details.

• The lifetime of the DC link bus capacitor (reservoir capacitor) can be estimated

The capacitor's condition compared with its initial state can be confirmed.

• Long-life cooling fan

Use of a long-life cooling fan (estimated service life: 7 years for operation at an ambient temperature of
40°C (104°F)) reduces maintenance cost.

• Recording and display of cumulative running time of the inverter

The inverter records and displays the accumulated running time of the inverter itself, the printed circuit
board and cooling fan.

• Alarm history for up to 4 latest alarms

The inverter records detailed information for up to 4 alarms that occurred most recently, which can also be
displayed on the LED.

Refer to Chapter 3, Section 3.3.6 "Reading alarm information."



• Lifetime forecast signal via transistor output

This signal is output when the reservoir capacitor in the DC link bus, the electrolytic capacitors on the
printed circuit board, or the cooling fans have been nearing the end of their service life.

Refer to function code E20 in Chapter 9, Section 9.2.2 "E codes (Extension terminal functions)" for



details.

Interface for peripheral devices and comprehensive protective functions

• All models are equipped with an inrush current suppression circuit.

FRENIC-Mini series features an inrush current suppression circuit as standard in all models to reduce the
cost of peripheral devices such as input magnetic contactor.

• Terminals for a DC reactor (DCR) provided as standard

Terminals for connection of a DCR, which are necessary for suppressing harmonics, are provided as
standard in all models.

• Input/output phase loss protective function

FRENIC-Mini series can detect output phase loss at all times during starting and running. This feature
assists you for keeping operation of your system stable.

• Switchable sink/source

The input/output mode (sink/source) of the digital input terminals can be switched by means of an internal
jumper switch. No engineering change is required in other control devices including PLC.

• Motor can be protected by a PTC thermistor

The motor is protected by PTC (Positive Temperature Coefficient) thermistor which detects the motor's
temperature and stops the inverter before the motor is overheated.

1-6

Flexible through optionals

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• Function code copy function

The optional remote keypad includes a built-in copy facility, so you can copy function code data set in a
source inverter and duplicate it into a destination inverter.

• Inverter support loader software available

The inverter support loader program (Windows-based), which simplifies the setting of function codes, is
provided as an option.

Refer to Chapter 5, "RUNNING THROUGH RS-485 COMMUNICATION (OPTION)" for details.



• Mounting on DIN rail

Using the rail-mounting base (option), the inverter can easily be mounted on a DIN rail [1.38 inch (35 mm)
wide].

Refer to Chapter 6, "SELECTING PERIPHERAL EQUIPMENT" for details.



• Easy replacement of older models with new ones

Using the mounting adapter (option) makes it possible to mount the latest models without drilling any
additional holes.

Refer to Chapter 6, "SELECTING PERIPHERAL EQUIPMENT" for details.



• Remote operation

Using the optional RS-485 communications card and remote keypad together with remote operation
extension cable enables you to easily operate the inverter from a remote location, such as outside the
control panel where the inverter is installed.

Refer to Chapter 5, "RUNNING THROUGH RS-485 COMMUNICATION (OPTION)" and



Chapter 6, "SELECTING PERIPHERAL EQUIPMENT" for details.

1.1 Features

Chap. 1 INTRODUCTION TO FRENIC-Mini

Wide variations

The wide range of models available in the FRENIC-Mini series of inverters is certain to flexibly meet your
various system needs.

• The 460 V series is available in addition to the 230 V series (3-phase, single-phase).

• Models with built-in EMC filter and built-in braking resistors are also available.

•

An optional RS-485 communications card enables your system to feature network driven
management.

Refer to Chapter 8, "SPECIFICATIONS" for details.



Global products

FRENIC-Mini series of inverters are designed for use in global market in conformity with the global
standards listed below.

• All standard models conform to the EC Directive (CE Marking), UL standards (UL-Listed) and
Canadian standards (cUL-Listed).

All standard FRENIC-Mini inverters conform to European and North American/Canadian standards,
enabling standardization of the specifications for machines and equipment used at home and abroad.

• If a model with a built-in EMC filter is used, the model conforms to the European EMC Directive.

1-7

1.2 Control System

This section gives you a general overview of inverter control systems and features specific to the
FRENIC-Mini series of inverters.

As shown in Figure 1.8, single- or three-phase commercial power is converted to DC power in the
converter section, which is then used to charge the capacitor on the DC link bus. According to control
commands or signals generated in the control logic, the inverter modulates the electricity charged in the
capacitor to PWM (Pulse Width Modulation) format and feeds the output to the motor. The modulation
frequency is called "carrier frequency." As shown in Figure 1.7, the voltage waveform of the modulated
power source produces pulse train with positive and negative polarity synchronized with the inverter's
output command frequency. The inverter feeds the produced output as drive power with sinusoidal current
waveform like that of ordinary commercial power lines.

PWM voltage waveform Current waveform

Figure 1.7 Output Voltage and Current Waveform of the Inverter

For the set frequency given in the control logic, the accelerator/decelerator processor calculates the
acceleration/deceleration rate required by run/stop control of the motor and transfers the calculated results
to the 3-phase voltage command processor directly or via the V/f pattern generator.

Refer to Chapter 4, Section 4.7 "Drive Command Controller" for details.



The FRENIC-Mini series features a simplified magnetic flux estimator which is added in the V/f pattern
processing section. This feature automatically controls the voltage level applied to the motor according to
the motor load so as to make the motor generate more stable and higher torque even during low speed
operation. This "Simplified Torque-Vector Control" is unique to Fuji inverters.

The control logic section, which is the very brain of the inverter, allows you to customize the inverter's
driving patterns using the function code settings.

Refer to Chapter 4 "BLOCK DIAGRAMS FOR CONTROL LOGIC" for details.



Figure 1.8 Simplified Control System Diagram of FRENIC-Mini

1-8

1.3 Recommended Configuration

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1.3 Recommended Configuration

To control a motor with an inverter correctly, you should consider the rated capacity of both the motor and
the inverter and ensure that the combination matches the specifications of the machine or system to be
used. Refer to Chapter 7, "SELECTING OPTIMAL MOTOR AND INVERTER CAPACITIES" for
details.

After selecting the rated capacity, select appropriate peripheral equipment for the inverter, then connect
them to the inverter.

Refer to Chapter 6, "SELECTING PERIPHERAL EQUIPMENT" and Chapter 8, Section 8.7



"Connection Diagrams" for details on the selection and connection of peripheral equipment.

Figure 1.9 shows the recommended configuration for an inverter and peripheral equipment.

Chap. 1 INTRODUCTION TO FRENIC-Mini

Figure 1.9 Recommended Configuration Diagram

1-9

Chapter 2

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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 7-segment LED monitor and keys on the keypad.

Contents

2.1 External View and Allocation of Terminal Blocks ...................................................................................... 2-1

2.2 LED Monitor, Potentiometer and Keys on the Keypad............................................................................... 2-2

2.1 External View and Allocation of Terminal Blocks

r

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2.1 External View and Allocation of Terminal Blocks

Figures 2.1 and 2.2 show the external and bottom views of the FRENIC-Mini.

(1) External and bottom views

Keypad

Nameplate

Main circuit terminal
block cover

Cooling fan

Heat sink

Control circuit terminal
bock cover

Figure 2.1 External Views of FRENIC-Mini

Barrie

for the RS-485

communications port*

Control circuit wire port

DB, P1, P (+) and N (-) cable port

L1/R, L2/S, L3/T, U, V, W,
grounding wire port

L1/R, L2/S, L3/T, P1, P (+),
N(-) wire port

DB, U, V, W,
grounding wire
port

Control circuit terminal
block cover

Chap. 2 PARTS NAMES AND FUNCTIONS

(a) FRN001C1S-2U (b) FRN002C1S-2U

(*When connecting the RS-485 communications cable, remove the control circuit terminal block cover and snip off the barrier provided
in it using nippers.)

Figure 2.2 Bottom View of FRENIC-Mini

(2) Allocation of terminals

RS-485 communications card
connector

Control circuit terminal
block

Grounding terminal

Power input terminal block

Inverter output terminal block

SINK/SOURCE jumper switch

DC reactor, braking resistor and
DC link bus terminal block

Grounding terminal

(FRN002C1S-2U)

Figure 2.3 Enlarged View of the Terminal Blocks

The above figures show three-phase power source models. The terminal allocation of the power input
terminals L1/R, L2/S, L3/T, and grounding terminals for single-phase models differs from that shown in
above figures.

Refer to Chapter 8 "SPECIFICATIONS" for details on terminal functions, allocation and



connection and to Chapter 6, Section 6.2.1 "Recommended wires" when selecting wires.
For details on the keys and their functions, refer to Section 2.2 "LED Monitor, Potentiometer and



Keys on the Keypad." For details on keying operation and function code setting, refer to Chapter 3
"OPERATION USING THE KEYPAD."

2-1

2.2 LED Monitor, Potentiometer and Keys on the Keypad

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As shown at the right, the keypad
consists of a 7-segment LED monitor,
a potentiometer (POT), and six keys.

The keypad allows you to run and stop
the motor, monitor running status, and
switch to the menu mode. In the menu
mode, you can set the function code
data to match your operating
requirements and monitor I/O signal
states, maintenance information, and
alarm information.

Table 2.1 Overview of Keypad Functions

Monitor, Potentiometer

and Keys

Four-digit, 7-segment LED monitor which displays the running status, data
settings, and alarm status of the inverter according to the operation modes*.

In Running mode, the monitor displays running status information (e.g.,
output frequency, current, and voltage). In Programming mode, it displays
menus, function codes and their data. In Alarm mode, it displays an alarm
code which identifies the error factor if the protective function is activated.

Program/Reset key

7-segment
LED monitor

Down key Up key Function/Data key

Figure 2.4 Keypad

Functions

PotentiometerRUN key

STOP key

Potentiometer (POT) which is used to manually set frequency, auxiliary
frequencies 1 and 2 or PID process command.

RUN key. Press this key to run the motor.

STOP key. Press this key to stop the motor.

/

UP/DOWN keys. Press these keys to select the setting items and change the
function data displayed on the LED monitor.

Program/Reset key. Press this key to switch the operation modes* of the
inverter.

Pressing this key in Running mode switches the inverter to Programming
mode and vice versa.

In Alarm mode, pressing this key after removing the error factor will switch
the inverter to Running mode.

Function/Data key.
Pressing this key in Running mode switches the information displayed

(output frequency (Hz), current (Amps) or voltage (V)).
Pressing this key in Programming mode displays the function code and sets

the data entered using

keys or the POT.

/

Pressing this key in Alarm mode displays information concerning the alarm
code currently displayed on the LED monitor.

*

FRENIC-Mini features three operation modes--Running, Programming, and Alarm modes. Refer to
Chapter 3, Section 3.1 "Overview of Operation Modes."

2-2

■ LED monitor

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2.2 LED Monitor, Potentiometer and Keys on the Keypad

In Running mode, the LED monitor displays running status information (output frequency, current or
voltage); in Programming mode, it displays menus, function codes and their data; in Alarm mode, it
displays an alarm code which identifies the error factor if the protective function is activated.

If one of LED4 through LED1 is blinking, it means that the cursor is at this digit, allowing you to change
it.

If the decimal point of LED1 is blinking, it means that the currently displayed data is a PID process
command, not the frequency data usually displayed.



Table 2.2 Alphanumeric Characters on the LED Monitor

Character 7-segment Character 7-segment Character 7-segment Character 7-segment

0

1

2

3







LED4 LED3 LED2 LED1

Figure 2.5 7-Segment LED Monitor

9

A

b

C



#C

D

%E

i

J

K

L

+
L

M

.N

r

S

T

u

T
U

6
7

Chap. 2 PARTS NAMES AND FUNCTIONS

4

5

6

7

8

Special characters and symbols (numbers with decimal point, minus and underline)

0. - 9.   - - _ _

■ Repeat function of / keys










d

E

F

G

H

F

'G

(H

)I
*J

M

O

n

o

P

q

P

Q

2R

S

V

W

X

y

Z

W

Y

Z
[
<



/ keys have a repeat function which helps you change displayed data speedily as follows:

Usually you press

If you hold down

/ keys once to increase or decrease the displayed value by 1, respectively.

either key so as to activate the repeat function, the displayed value will keep changing
in steps of 1 speedily. Note that when changing some function code data during running of the inverter
(not always possible), the displayed data will keep changing more slowly. This is to ensure safe and
stable operation.

2-3

■ Continuous holding-down function for Program/Reset key

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Holding down the key longer (approx. one second or longer) moves the cursor on the LED monitor.
In Running mode, the cursor moves along digits; in Programming mode, it moves not only along digits
but to the next function code.

■ Simultaneous keying

Simultaneous keying means depressing two keys at the same time (expressed by "+"). FRENIC-Mini
supports simultaneous keying as listed below.

(For example, the expression "

+ keys" stands for pressing the key while holding down the

key.)

Operation modes Simultaneous keying Used to:

Running mode Control entry to/exit from jogging operation.

Programming mode

Alarm mode + keys Switch to Programming mode.

+ keys

+ keys

Change special function code data.

(Refer to codes F00 and H03 in Chapter 9
"FUNCTION CODES.")

2-4

Chapter 3

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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.

Contents

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"

3.3.6 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

........................................................... 3-21