Before carrying out installation, wiring, mainte- nance or inspection of the drive, read this in- struction manual thoroughly to gain a full under- standing of the correct operation procedures. Make sure that you have read all product details, safety information, warnings and cautions before use. The following classifications for warnings and cautions are used throughout this manual.

WARNING:

Denotes operating procedures and practices that may result in severe injury or loss of life if not correctly followed.

CAUTION:

Denotes operating procedures and practices that, if not strictly observed, may result in per- sonal injury or damage to the equipment.

WARNING:

FIRE AND PERSONAL INJURY HAZARD

This drive is designed for variable-speed opera- tion of three-phase induction motors. It cannot be used with single-phase motors or for any other applications, otherwise fire may result.

The drive cannot be used by itself for elevators, life-preservation equipment or other equipment which is directly related to human safety. In such situations, sufficient consideration should be given to overall system configuration, not just to the drive, otherwise serious accidents could result.

INSTALLATION

WARNING:

FIRE AND PERSONAL INJURY HAZARD

Install the drive to a non-flammable surface such as a metal surface, otherwise fires may result.

Do not place the drive near flammable materials, otherwise fires may result.

Do not hold the drive by its cover when trans- porting. Otherwise the drive could be damaged and cause injury to personnel.

Do not let any scraps of thread, paper, sawdust, dirt, metal shavings or other foreign objects get

inside the drive or onto the cooling fins, other- wise fire or problems with operation may result. AC input fuses are required to validate UL listing of this device.

Do not install and operate the drive if it is dam- aged or if some of the parts are missing. Doing so may result in severe personal injury.

Do not touch the drive cooling fin because the cooling fin reaches high temperatures during operation, otherwise personal injury may result.

Install the drive in the environment of pollution degree 2. If environment is pollution degree 3 or 4, the drive should be installed in a cabinet of IP54. Required for CE Certification.

WIRING

WARNING:

FIRE AND ELECTRIC SHOCK HAZARD.

When connecting the drive to a power supply, be sure to connect it via a circuit breaker, a leakage current breaker or a fuse, otherwise fires may result.

AC input fuses are required to validate the UL listing of the drive.

Use only fuses and circuit breakers with rated capacities that are suitable for use with the drive. Failure to do so may result in fire.

Connect the drive with a secure ground, other- wise electric shocks or fires may result.

Wiring work should only be carried out by suit- ably qualified personnel, otherwise electric shocks may result.

Make absolutely sure that the power supply is turned off (open) before wiring, otherwise electric shocks may result.

Wiring work should only be carried out after the drive has been installed, otherwise electric shocks or injury may result.

CAUTION:

Check that the phase and voltage of the AC power supply being connected matches the input phase and rated input voltage of the drive. Using an improper power supply may cause injury or damage to the equipment.

Do not connect AC power to the output termi- nals (U, V, W) otherwise injury may result.

The drive, motor and wiring produce electromag- netic noise during operation. Make sure that this does not interfere with the operation of sensors or other equipment nearby, otherwise accidents may result.

OPERATION

WARNING:

ELECTRIC SHOCK HAZARD

Always install the drive cover before turning on the power supply. In addition, do not remove the drive cover while the power is on. Failure to observe these precautions may result in electric shocks.

Do not operate any of the switches with wet hands, otherwise electric shocks may result.

WARNING:

FIRE AND PERSONAL INJURY HAZARD

If the retry function has been activated and a trip occurs, the drive will restart automatically de- pending on the cause of the trip. Make sure that the system is set up properly so that there will be no danger to personnel when the drive starts.

The STOP key is only effective when keypad panel operation has been selected in the func- tion settings. A separate switch should be installed for emergency stopping purposes.

If an alarm reset is carried out while a run signal (FWD/REV) is being input, the drive will suddenly restart. Always check that the run signal is not being input before carrying out the alarm reset, otherwise accidents may occur.

Never touch the drive terminals while the power is fed to the drive, regardless of whether the drive is running or not.

CAUTION:

Do not touch the cooling fins, as they become hot during drive operation.

Because it is relatively easy to set the drive to high speed operation, be sure to check the capacity of the motor and the equipment being operated before changing the drive function setting.

The drive braking function cannot be substituted for mechanical means. Attempting to do so may result in injury.

MAINTENANCE, INSPECTION AND PART

REPLACEMENT

WARNING:

ELECTRIC SHOCK HAZARD

Wait at least five minutes after turning off the power before carrying out inspection. Check that the charge indication lamp has gone out. Do not touch the drive parts if the lamp is still lit, other- wise electric shocks may result.

Maintenance, inspection and parts replacement should only be carried out by suitably qualified personnel. Remove any metallic accessories such as watches and rings before starting work, and use only properly insulated tools, otherwise electric shocks may result.

DISPOSAL

CAUTION

Disposal of the drive should be entrusted to a suitably-qualified disposal agency, otherwise injury may result.

PACKING

CAUTION

Do not stand or sit on the drive as injury may result.

The number of packing cartons that can be stacked together is printed on the packing container. Do not stack the containers any higher than this or injury may result.

UL/CSA

WARNING / AVERTISSEMENT

Hazard of electrical shock. Disconnect incoming power before working on this control.

Risque de choc electrique. Couper l???alimentation avant le depannage de sette commande.

More than one live circuit. See diagram. Cet equipment renferme plusieurs circuits sous tension. Voir le schema

CAUTION ATTENTION

Dangerous voltage exists until charge light is off. Prede tensions dangereuses tant que le voyant n???est pas eteint.

Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes. 240V maximum.

???Use 60/75?? C copper wire only.

???Use Class 1 wire only.

???Open type equipment

???Tightening torque and wire range for field wiring terminals are as follows:

Use the listed quick-acting fuse in series. Fac- tory recommendation is a Bussman type JKS or equivalent. Fuses are required to validate the UL and CSA listings.

FVRF12C9S-7UX20

FVRF25C9S-7UX20

FVRF50C9S-7UX20

FVR001C9S-7UX20

FVR002C9S-7UX30

Field wiring connection shall be made by a UL listed and CSA Certified closed-loop terminal connector sized for the wire gauge involved.

Connector must be fixed using the crimp tool specified by the connector manufacturer.

OTHER

WARNING:

FIRE AND PERSONAL INJURY HAZARD

Do not carry out any modifications to the drive. Doing so may result in electric shock and injury.

GENERAL CAUTION

All of the illustrations in this instruction manual show the drive with the covers and other protec- tive equipment removed in order to facilitate explanation of detailed parts of the drive. Be absolutely sure to return all covers and protective equipment to the prescribed positions before operating the drive, and make sure that all opera- tions are carried out in accordance with the instructions in this manual.

1. Inspection Upon Receipt

Please inspect the following items upon receipt of your drive.

???Check the name plate to insure the specifica- tions correspond to those ordered.

???Inspect the unit for damage which may have occurred during shipping.

If you have any problems or questions regarding the drive, please contact the nearest Fuji sales office or the distributor where the unit was purchased.

Nameplate

1. Type

Drive Series

F V R F 2 5 C 9 S 7 U X

Power Series: 200V UX Series Applicable motor output (Hp)

3. Warning and Caution

Improper wiring will result in damage to, and failure of the unit. Please carefully note the items listed below, and use the unit as indi- cated.

2.Phase: 1AC - Single-phase

3.Voltage range: 220V - 240V AC200V Series

4.Frequency: 50/60Hz

5.Rated output capacity

6.Rated output current

7.Output frequency range: 1- 120 Hz

8.Serial No.

2. Part Names

4

2

FVR-C9S

3

1

2.Keypad Panel

3.Frequency Setting VR

4.Mounting Screw Holes

5.Drive Cover Screw

WARNING AND CAUTION

1.Do not connect the power supply to voltage that exceeds the standard speci- fication voltage with permissible fluctua- tion. (Permissible voltage: AC220V - 240V)

2.Do not connect power supply to the drive output terminals (U, V, W). Connect power supply only to the power terminals (L1, L2)

3.Whenever removing the drive cover, always switch off the power supply. Do not switch on the power supply to the drive with the drive cover removed.

4.Do not touch the live part until the CRG lamp located above the main circuit terminals goes out.

5.Avoid using a magnetic contactor (ON/ OFF) installed in the line side of the drive for RUN and STOP. Use the FWD-CM (forward) and REV-CM (reverse) terminals for RUN and STOP.

6.Do not connect a power factor correcting capacitor to the output side of the drive.

7.Do not perform a megger test between the drive terminals or on the control circuit terminals.

0.24 (6.2)

2 - dia. 0.20 (2 - dia. 5)

1.97 (50)

5.12 (130) 3.15 (80)

0.20 (5)

0.45 (11.5)

DWG 2: FVR002C9S-7UX

6. Installation Instructions

Installation Conditions

Install the drive in a location which meets the following requirements:

???The ambient temperature should be be- tween -10??C and +50??C.

???Install the drive in the environment of pollution degree 2. If environment is pollu- tion degree 3 or 4, the drive should be installed in a cabinet of IP54.

???Install the drive in the atmospheric pres- sure of 900mbar or more.

???Install the drive in the vibration of 232 inches/s2 (5.9m/s2) or less.

Mounting plate: Heat sink temperature will reach +90??C during operation. Please use thermostable material for drive mounting plate.

Multi-mounting: When 2 or more drives are installed within the drive switchboard, ar- range them side by side, keeping space (shown in the above figure) between each drive. If the drives must be lined up vertically, provide adequate ventilation so that the hot air from each drive will not affect the one above it.

7. Wiring

Perform wiring in accordance with the fol- lowing procedure:

Mounting Direction and Space

3.94???

(10cm)

CLOSED OPEN

3.94???

(10cm)

NOTICE: The durability and reliability of the drive will be affected by the ambient tem- perature. Do not place the unit where ambi- ent temperature is not proper.

Direction: Insert M4 size screws in the mounting screw holes in the left upper and right lower of the drive, and install the drive with these screws. Install the drive vertically. Horizontal or other positional installation will cause the drive to overheat.

Space: The drive will generate heat during operation. Allow sufficient space around the unit as shown in the above figure.

1) Remove the cover mounting screw at the center of the cover.

FVR-C9S

CLOSED OPEN

Cover Mounting Screw

2) Hold the lower end of the cover, lift it up and remove the cover

2

1

Side view of inverter

3) Remove the keypad panel from the main unit, and disconnect the harness from the CN2 at the same time.

Disconnect

CN 1

CRG Lamp

4) Arrange the main circuit and the control circuit wiring as follows.

Note 3) Connect the power supply of over voltage category II. If the power supply is over voltage category III, place the devices to limit the over voltage below 2.5kV.

Required for CE Certification.

5) Reinstall the cover. Connect the harness of the keypad panel to the CN2 on the main unit, then reinstall the keypad panel fitting it onto the guide pins.

Note 2

6) As shown below, reinstall the cover onto the drive main unit, and fix it with the mount- ing screw.

1.Motor coast-to-stop

2.Reset signal

3.Reverse-direction operation command

4.Forward-direction operation command

5.External alarm

6.Frequency setting VR

7.Combined alarm relay output

Note 1) FWD and THR are connected to CM at the factory. In this condition, starting/stopping can be performed via RUN/STOP keys on the keypad panel.

Note 2) In case of using an external potenti ometer, remove the connector which the keypad panel and the CN2 on the drive main unit are connected.

1

2

Side view of inverter

Power Supply

AC220 - 240V

50/60 Hz

1-phase

FAB

L2W

C1

30A

30B

FWD

REV 30C

RST

BX

CM

THR

FM 10V 1mA

???

PE

The control circuit terminal wiring should be kept as far as possible from the main circuit wiring to prevent operational error due to noise interference. Never install them in the same duct or conduit. (A separation distance of 4 inches [10cm] or more is recom- mended.) If the control circuit wiring must cross the main circuit wiring, make sure it crosses at a right angle.

Use shielded, twisted wire for the control circuit wiring , which should be as short as possible (65 feet [20m] or less).

Install a surge absorber in parallel with any magnet contactors, solenoids, relays or timer coils, which are close to the drive.

Long wiring lengths between the motor and the drive will result in increased capacitance and leakage current. This may cause earlier activation of such protective functions as: overcurrent protection, overheating protec- tion and electronic thermal overload, or the error in current detection may become large. To avoid these, adjust the length of wiring between the drive and the motor so that is does not exceed the length shown below.

FVRF12C9S-7UX : 165 feet (50m)

FVRF25 to 002C9S-7UX : 325 feet (100m)

11. Operation

Pre-Operation Inspection

???Check for wiring errors.

???Check that all loose wire stands, metal chips and unnecessary screws, etc. have been removed.

???Check that no screws, terminals, etc. are loose.

???Check that the wire ends of crimp terminal are not in contact with other terminals.

???The drive is shipped with a factory in- stalled jumper, between FWD-CM. Only forward operation is possible. To enable reverse operation, remove the jumper from FWD/CM and install the jumper between REV-CM.

???RUN/STOP by terminal operation (F02 : 1)

Note: Open FWD and REV terminals when changing F02 data. Data cannot be changed if not open.

Test Run Check Points

???Smooth rotation and correct rotation direction.

???No abnormal vibrations and noise from the motor.

???Smooth acceleration and deceleration.

Frequency Setting Method

???Frequency setting by potentiometer con- trol (factory preset at the time of ship- ment; F01:1). As wired at the factory, frequency setting can be performed by turning the potentiometer control knob on the keypad panel. Turn the potentiometer control knob clockwise to increase fre- quency.

???Frequency setting by digital signal (F01 : 0). With the function F01 set to 0, fre- quency can be increased or decreased by the

UP/DOWN) keys on the keypad panel. UP: Frequency up

DOWN: Frequency down

RUN/STOP Method

???RUN/STOP by keypad panel operation (Factory preset at the time of shipment F02:0).

Frequency

Forward

Frequency

Reverse

FWD-CM ON

Digital monitor:

In program mode, the key- pad displays the various function codes and data values. During operation, it displays the output fre- quency, current, voltage, etc. If a fault occurs, the causes of the problem will be displayed as a code.

PROGRAM key (RESET key): Normal mode or program setting mode select key. If a fault occurs, this key is used to reset the fault.

8. 8. 8.

FVR-C9S

RUN key: This key is used for starting operation. The LED (green) lights up during operation. This key does not function when terminal operation control F02_ _ 1 is selected.

STOP key: This key is used for stopping operation. This key does not function when terminal operation control F02 _ _1 is selected.

FUNCTION key (DATA key):

During normal mode, this key can be used to change the display unit (frequency display and output current display) while operation is either stopped or running. During the pro- gram setting mode, this key can be used to read and write the function codes and data.

UP/DOWN keys: These keys increase or decrease the frequency. When unit is in program setting mode, they change the function code or data values.

Controlling Method for Keypad Panel

1) Monitor change

During the normal mode, frequency display and output current display can be changed by pressing the FUNC/DATA key.

2) Run/Stop

F U N C

D ATA

F U N C

D ATA

Drive frequency (Hz)

Drive frequency (Hz)

F 2 7 THR Terminal Function

Bias

The purpose of the following section to provide specific instructions to the user of the FVR-C9S-7UX drive regarding warranty administration and how to obtain assistance on both in-warranty and out-of-warranty equipment.

If assistance is required to determine war- ranty status call:

Technical Services

GE Fuji Drives USA, Inc.

1-540-387-5739

24-hour Emergency 1-540-387-8292

Warranty Coverage

The warranty set forth in Section 1 of FN-1090 (1/91) of GE???s Condition of Sale covers all major parts of the drive such as the main printed circuit boards, transistor modules, etc. The warranty covers replace- ment of the entire drive.

???Warranty period is 12 months after installa- tion or 18 months after shipment from the Company, whichever occurs first.???

Before calling the number at left to deter- mine warranty status, the drive serial number will be required. This is located on the drive nameplate. If the drive is still under warranty, further information will be required per the ???In-Warranty Failure Checklist??? shown on page 36 of this instruction book.

Out-of-Warranty Procedures

If a defective drive is out-of-warrant contact an Authorized GE Fuji Service Provider for repair or an Authorized GE Fuji Distributor for replacement.

Motors

Repairs on motors are generally handled by the motor manufacturer. For specific instruc- tions on your motor, call the distributor from which it was purchased and be prepared to furnish complete nameplate data.

1. General

In accordance with the provisions described in the European Commission Guidelines Document on Council Directive 89/336/EEC, Fuji Electric Co., Ltd. has chosen to classify the FVR-C9S-7UX range of drives as ???Com- plex Components???. Classification as ???Com- plex Components??? allows a product to be treated as ???apparatus???, and thus permits compliance with the essential requirements of the EMC Directive to be demonstrated to both an integrator of FVR drives and to his customer or the installer user. FVR drives up to 2 Hp are supplied ???CE-marked???, signifying compliance with EC Directive 89/336/EEC when fitted with specified filter units installed and earthed in accordance with this sheet. This specification requires the following performance criteria to be met.

Immunity : EN50082-2

Emissions : EN50081-1

2. RFI Filters

It is strongly recommended that the appro- priate FVR input filter is used, as shown in the followings, to limit RF current flowing into the main supply circuit. Without an input filter a FVR installation may not meet statu- tory requirement. FVR drives contain high power semi-conductor devices which are switched at high speeds to synthesis a near- sinusoidal current waveform across the frequency range of the output. Rapidly- changing voltages and currents will generate some degree of electromagnetic emission. Emissions will be predominantly conducted through the motor and the mains supply cables, although some radiated emissions will be detected in close proximity to the drive system. It is essential that precautions are taken both at the design stage and at the time of installation to prevent radio fre- quency interference (RFI) from the drive system affecting sensitive equipment in close proximity.

3. Recommended Installation Instructions

It is necessary that to conform to the EMC Directive, these instructions must be fol- lowed. Follow the usual safety procedures when working with electrical equipment. All electrical connections to the filter, drive and motor must be made by a qualified electrical technician.

1)Check the filter rating label to ensure that the current, voltage rating and part number are correct.

2)The back panel of the wiring cabinet of board should be prepared for the mounting dimensions of the filter. Care should be taken to remove any paint etc. from the mounting holes and face area around the hole of the panel. This will ensure the best possible earthing of the filter.

3)The filter should then be securely mounted in position, and the drive mounted to the front of the filter with the screws provided.

4)Connect the incoming mains supply to the filter terminals marked ???LINE??? and earth any cables to the earth stud provided. And fit the Input Ferrite Ring (if required two ferrite rings, refer to table 1), then connect the filter terminals marked ???LOAD??? to the mains input of the drive using short length of appropriate gauge wire.

5)Fit the Output Ferrite Ring as close to the drive as possible and connect the motor. Armored or screened cable should be used with the 3 phase conductors only passing twice through the center of the Output Fer- rite Ring. The earth conductor should be securely earthed at both drive and motor ends. The screen should be connected to enclosure.

6)It is important that all lead length are kept as short as possible and that incoming mains and outgoing motor cables are kept well separated.

7)Segregate power cables from control wiring as possible as you can, and avoid parallel cable runs to minimize ???noise cou- pling???. Wherever runs of power and control cable must cross, try to achieve this at right angles.

8) FVR drives should be installed, and are designed to operate, within an electrically shielded metal enclosure.

The RFI filters range are designed especially for the FVR drive and help to ensure EMC compliance of machinery an installations using the drives. The drives may be mounted on top of the filter using the integral fixing positions, the intention being that valuable space inside wiring cabinets may be saved. (Refer to Fig. 1 and Table 1)