Fuji Frenic Mega Manual

The Fuji Frenic Mega is a high-performance industrial inverter drive designed for precise motor control applications. This advanced AC drive features robust construction, comprehensive control capabilities, and user-friendly programming interface. Below are key sections covering safety guidelines, technical specifications, installation procedures, parameter settings, operation modes, troubleshooting, and maintenance protocols.

Product Overview

The Fuji Frenic Mega series represents cutting-edge inverter technology with enhanced performance characteristics and operational flexibility for industrial applications.

Feature	Description
Control Method	PWM (Pulse Width Modulation) with voltage/frequency control
Frequency Range	0.1 to 400 Hz adjustable output frequency
Input Voltage	200-240V AC, 3-phase, 50/60Hz
Output Voltage	0 to input voltage, 3-phase
Control Modes	V/F control, sensorless vector control
Protection Features	Overcurrent, overvoltage, undervoltage, overload, overheating
Communication	RS-485, Modbus RTU protocol
Digital Operator	LCD display with keypad for parameter setting
Braking Options	Regenerative braking, DC injection braking
Environmental Rating	IP20 protection class

Safety Precautions

Critical safety information for proper installation and operation of the Fuji Frenic Mega inverter.

1. Disconnect all power sources before installation or maintenance.
2. Ensure proper grounding according to local electrical codes.
3. Install in well-ventilated area to prevent overheating.
4. Use appropriate personal protective equipment during installation.
5. Verify motor compatibility before connection.

WARNING! High voltage present even after power shutdown. Wait at least 10 minutes before touching internal components. Only qualified personnel should perform installation and maintenance.

Installation Guidelines

Proper installation procedures to ensure optimal performance and longevity.

1. Mounting: Install on vertical surface using specified mounting holes.
2. Clearance: Maintain minimum 100mm clearance on all sides for ventilation.
3. Environment: Avoid locations with excessive dust, moisture, or corrosive gases.
4. Temperature: Operating ambient temperature 0°C to 40°C (32°F to 104°F).
5. Vibration: Maximum allowable vibration 5.9 m/s² (0.6G).

CAUTION! Do not install in direct sunlight or near heat sources. Ensure proper cable routing to prevent electromagnetic interference.

Technical Specifications

• Model Series: Frenic Mega (FRN-XXXXX series)
• Rated Capacity: 0.4kW to 55kW (varies by model)
• Overload Capacity: 150% of rated current for 60 seconds
• Carrier Frequency: 0.5 to 15 kHz (adjustable)
• Acceleration/Deceleration: 0.1 to 3600 seconds (programmable)
• Control Accuracy: Digital setting: ±0.01% of maximum frequency
• Digital Inputs: 7 programmable multi-function terminals
• Analog Inputs: 2 channels (0-10V DC, 4-20mA)
• Relay Outputs: 2 programmable relay contacts
• Display: 4-digit LED/LCD with status indicators

Wiring Connections

Proper wiring procedures for main circuit and control circuits.

Main Circuit: R/L1, S/L2, T/L3 (input); U/T1, V/T2, W/T3 (output); P/+ , N/- (DC bus); P/+ , DB (braking resistor)

Control Terminals: Forward/Reverse run, multi-speed selection, analog frequency reference, relay outputs, communication ports.

1. Use copper conductors only with proper current rating.
2. Apply appropriate torque to terminal screws (1.2 N·m).
3. Install noise filter on input side for electromagnetic compatibility.
4. Use shielded cables for control signals with proper grounding.
5. Separate power and control wiring to prevent interference.

Tip: Always verify wiring before applying power. Use wire ferrules for stranded conductors.

Parameter Settings

Essential parameter configuration for basic operation and advanced functions.

1. Basic Settings: F01 (frequency reference), F02 (operation method), F03 (maximum frequency)
2. Motor Parameters: P01 (motor capacity), P02 (number of poles), P03 (rated current)
3. Acceleration/Deceleration: F07 (acceleration time 1), F08 (deceleration time 1)
4. Protection Settings: F10 (electronic thermal), F11 (overcurrent protection)
5. Multi-function Inputs: E01-E07 (terminal functions selection)
6. Multi-function Outputs: E20-E27 (relay and transistor outputs)
7. Communication Settings: C01 (communication protocol), C02 (station number)
8. Application Functions: H01-H99 (special application parameters)

WARNING! Incorrect parameter settings may cause equipment damage or unsafe operation. Always verify settings before operation.

Operation Modes

Various operation modes available for different application requirements.

Mode	Description	Application
Keypad Operation	Control via digital operator keys	Manual testing and setup
External Terminal	Control via external signals	Automated systems
Communication Control	RS-485 network control	Centralized control systems
Analog Reference	0-10V/4-20mA speed control	Process control applications
Multi-step Speed	Pre-set speed selection	Fixed process sequences
PID Control	Process feedback control	Pressure, flow, temperature control

Digital Operator Functions

Comprehensive guide to using the digital operator for monitoring and programming.

1. RUN/STOP: Start and stop motor operation
2. MODE: Navigate between monitoring and parameter modes
3. UP/DOWN: Adjust frequency or parameter values
4. SET: Confirm parameter changes
5. SHIFT: Move cursor between digits
6. RESET: Clear faults and reset drive
7. Display Modes: Output frequency, output current, set frequency, fault history
8. Parameter Access: Quick access to frequently used parameters
9. Copy Function: Transfer parameters between units

CAUTION! Parameter changes take effect immediately. Ensure safe conditions before making operational changes.

Maintenance & Inspection

Regular maintenance schedule and inspection procedures.

• Daily: Check for abnormal noise, vibration, or overheating
• Monthly: Clean air vents and check cooling fan operation
• Quarterly: Check terminal connections for tightness
• Annually: Measure main circuit insulation resistance
• Every 2-5 Years: Replace cooling fan and check DC bus capacitors

WARNING! Always disconnect power before performing maintenance. Use proper lockout/tagout procedures.

Troubleshooting Guide

Fault Code	Description	Corrective Action
OC (Overcurrent)	Output current exceeds limit	Check motor connections; increase acceleration time; verify load conditions
OV (Overvoltage)	DC bus voltage too high	Increase deceleration time; install braking resistor; check input voltage
UV (Undervoltage)	DC bus voltage too low	Check input power; verify no phase loss; check main circuit fuses
OH (Overheat)	Heat sink temperature high	Clean air vents; check cooling fan; reduce carrier frequency; verify ambient temperature
GF (Ground Fault)	Motor ground fault detected	Check motor insulation; inspect motor cables for damage
PUF (Fuse Blown)	Main circuit fuse open	Check for short circuit in output; replace fuse after identifying cause

Reset Procedure: Clear fault conditions before restart. Identify and correct root cause to prevent recurrence.

Warranty Information

Fuji Electric provides comprehensive warranty coverage for the Frenic Mega series.

• Warranty Period: 18 months from date of purchase or 24 months from date of manufacture
• Coverage: Defects in materials and workmanship under normal use
• Exclusions: Improper installation, misuse, unauthorized modifications, normal wear
• Service: Contact authorized Fuji Electric service centers for warranty claims
• Technical Support: Available through regional distributors and service partners

For technical assistance or warranty service, contact Fuji Electric at +81-3-5435-7251 or visit www.fujielectric.com