Fuji Electric FRENIC-Lift LM2A Starting Guide

0. About this manual

Thank you for choosing the FRENIC-Lift (LM2) inverter series. This series is specially designed for the operation of induction and permanent magnet synchronous motors used in lift applications. It also allows for the control of induction motors without an encoder (open loop), achieving good performance and high positioning accuracy at stop.

This starting guide provides basic information and explanations for the connection and commissioning of the FRENIC-Lift (LM2).

Note: This guide is based on firmware version 0900 or later. For other software versions, please contact Fuji Electric's technical department.

Firmware version (ROM) can be monitored on TP-E1U (5_14) and TP-A1-LM2 (PRG > 3 > 4).

For extended information, refer to:

• FRENIC-Lift Reference Manual INR-SI47-1909_-E (RM)
• FRENIC-Lift Instruction Manual INR-SI47-1894_-E (IM)

1. Safety information

Read this manual thoroughly before installation, connections, operation, or maintenance. Ensure you understand the device and all safety information before operating the inverter. Safety precautions are divided into two categories:

▲ WARNING: Failure to heed this information may lead to dangerous conditions, possibly resulting in death or serious bodily injuries.

▲ CAUTION: Failure to heed this information may lead to dangerous conditions, possibly resulting in minor or light bodily injuries and/or substantial property damage.

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

Application Safety

• WARNING: FRENIC-Lift is designed for three-phase motors. Do not use for single-phase motors or other purposes, as this could cause fire or accidents.
• WARNING: FRENIC-Lift may not be used for life-support systems or other purposes directly related to human safety. Install safety devices for applications where serious accidents or material losses are foreseen due to failure.

Installation Safety

• WARNING: Install the inverter on a non-flammable material such as metal to prevent fire. Do not place flammable objects nearby.
• CAUTION: Do not carry the inverter by its terminal block cover during transportation, as this could cause it to drop and result in injuries.
• CAUTION: Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from entering the inverter or accumulating on the heat sink, as this could result in fire or accidents.
• CAUTION: Do not install or operate a damaged or incomplete inverter, as this could cause fire, accidents, or injuries.
• CAUTION: Do not stand on shipping boxes. Do not stack boxes higher than indicated to prevent injuries.

2. Conformity to European standards

The CE marking on Fuji Electric products indicates compliance with the essential requirements of the Electromagnetic Compatibility (EMC) Directive 2004/108/EC and the Low Voltage Directive 2006/95/EC.

Inverters with built-in EMC filters are compliant with EMC directives. Inverters without built-in EMC filters can be made compliant by connecting an optional EMC compliant filter.

FRENIC-Lift (LM2) inverter series comply with the following council directives and their amendments:

• Electromagnetic Compatibility Directive: 2014/30/EU
• Low Voltage Directive: 2014/35/EU
• Machine Directive: 2006/42/EC

For conformity assessment, the following standards were considered:

• EMC: EN61800-3:2004+A1:2012, EN12015:2014, EN12016:2013.
• Electrical Safety: EN61800-5-1:2007
• Functional Safety: EN61800-5-2:2007 SIL3, EN ISO13849-1:2008 PL=e, Cat.3 Safe Torque Off

CAUTION: The FRENIC-Lift (LM2) inverter series are categorized as C2 or C3 according to EN61800-3:2004+A1:2012. In domestic environments, appropriate countermeasures may be needed to reduce or eliminate noise emitted from these products.

3. Technical data

3.1 Specifications

Table 3.1 provides general specifications for the FRENIC-Lift LM2A.

Conformity standard

• Lift Directive (95/16/EC)
• Machinery Directive
• Low Voltage Directive
• EMC Directive

Enclosure (IEC60529)

• Main body: IP20
• Heat sink: IP00

Cooling method

• Fan cooling

Notes:

• ¹ Rated capacity is calculated by regarding the output rated voltage as 440 VAC.
• ² Output voltage cannot exceed the power supply voltage.
• ³ These values correspond to the following conditions: carrier frequency is 10 kHz (2 phase modulation) and ambient temperature is 45°C. Select the inverter capacity such that the square average current during operation is not higher than 80% of the rated current.
• ⁴ Voltage unbalance [%] = (Max.voltage [V] - Min.voltage [V])/ Three-phase average voltage [V] x 6 (IEC61800-3). Applies only to 3ph 400 VAC input supply.
• ⁵ The power supply capacity is 500kVA (ten times the inverter capacity when the inverter capacity exceeds 50kVA), and the value of the power supply impedance is %X=5%.
• ⁶ The admissible error of minimum resistance is ±5%.
• ⁷ Braking time and duty cycle (%ED) are defined by cycle operation at the rated regenerative power.
• ⁸ Variations (Voltage: +10 to -10%, Frequency: +5 to -5%)

3.2 External dimensions

Table 3.2 shows the external dimensions and frame definitions for the FRENIC-Lift LM2A.

Frame 1 and frame 2 can be called as well from now on Book type.

Diagrams showing external dimensions for different frame types are provided.

4. Removal and attachment of front cover

Follow the procedures shown in the figures to remove and attach the front cover for each frame. It is assumed that the inverter has already been installed.

Figure 4.1: Removing front cover step by step (Frame 1 & 2 – Book type)

Figure 4.2: Removing front cover step by step (Frame 3)

Figure 4.3: Removing front cover step by step (Frame 4 & 5)

5. Connections

5.1 Control signals connection

Two frame typologies are identified in the LM2A: book type (frames 1 and 2) and standard frame (frames 3 to 5). Different connection types are shown in figures 5.1 and 5.2.

Figure 5.1: Power terminals connection in book type frames (frame 1-2).

Figure 5.2: Power terminals connection in frames 3~5.

Notes on power terminals:

• *1: Jumper to connect/disconnect internal EMC filter.
• *2: DC Reactor terminals: For frames 1 and 2, use a jumper between P2 and P3 if no DC Reactor is installed. For frames 3-5, remove the metal plate jumper between P1 and P(+) if a DC Reactor is installed.
• *3: Use metal plates on removable terminals to connect the shield using metal cable ties.
• *4: If not installing the two MC between motor and inverter, follow the procedure in document "AN-Lift2-0001".
• *5: External MC for PMS motor phase short-circuit is optional.
• *6: Removable terminals.

5.2 Control signals connection

Figure 5.3 shows the control terminals on the electronic boards, divided into control board (fixed) and I/O terminals board (removable). For detailed information on wiring and terminal functions, refer to the following sub-chapters.

Figure 5.3. Control board and I/O terminals board terminals

All examples are based on FRENIC-Lift (LM2A) default settings. For other functions, refer to the FRENIC-Lift RM document.

5.3 Use of input terminals for speed set point selection

Table 5.2 shows the binary combination for speed selection, mapping input terminals (X1, X2, X3) to selected speeds and their corresponding speed set point functions.

Signals can be adapted by modifying settings on parameters L11 to L18. Table 5.3 provides an example of binary combination for speed selection modification.

5.4 Control terminals description

Control terminals include digital signals (input/output), analog signals (input/output), and communication ports. All inputs and outputs are programmable.

5.4.1 Analog inputs

Analog inputs allow setting motor speed and torque bias without steps. Selection between voltage or current is made via slide switch SW4. Terminal [NTC] is for PTC/NTC thermistor connection for motor overheat protection.

5.4.2 Digital inputs

Digital inputs can operate in NPN or PNP logic, selected by slide switch SW1. Factory setting is PNP (Source) Logic.

Table 5.4 describes the function of each digital input terminal:

• FWD: Clockwise motor rotation.
• REV: Anticlockwise motor rotation.
• CM: Common 0 VDC.
• X1 to X3: Digital inputs for speed selection.
• X4 to X7: Configured as "BATRY" for Battery or UPS operation (Rescue operation).
• X8: Inverters enable terminals (IGBT drives habilitation). These terminals comply with STO SIL 3 function.
• EN1 & EN2: Compliant with STO SIL 3 function. Can be used to substitute two contactors between the inverter and the motor. Refer to "AN-Lift2-0001" for details. Incorrect usage can lead to inverter trips or damage. These terminals are fixed to SOURCE logic.

Figures 5.4 and 5.5 show connection examples using free potential contacts and external power supply.

Figure 5.6 shows recommended wiring of EN circuit terminals.

Table 5.5 provides electrical specifications for digital inputs using PNP (Source) Logic.

5.4.3 Relay output

Terminals Y3(A/C), Y4(A/C), Y5(A/C) and 30(A/B/C) have factory-configured functions described in Table 5.6. Other functions can be set using functions E22 to E30.

Table 5.6: Default setting and specifications of relay outputs.

5.4.4 Transistor output

Terminals Y1 and Y2 are configured for Main MC control function (SW52-2) and Anticipated door opening control (DOPEN). Common for transistor outputs is CMY.

Table 5.7 provides default settings and specifications of transistor outputs. Table 5.8 shows electrical specifications.

Inductive loads should not be connected directly; use a relay or optocoupler.

5.4.5 Communication ports

FRENIC-Lift (LM2) has three built-in communication ports: CAN bus (TERM1), RS-485 port 1 (RJ-45), and RS-485 port 2 (DX+, DX-).

Port 1: Keypad, Modbus RTU, Loader software, DCP.

Port 2: Modbus RTU, Loader software, DCP.

Port 3: CAN bus.

Refer to the specific manual for communication protocols.

6. Hardware configuration

Up to 5 slide switches on the control and I/O terminals boards allow different configurations. Table 6.1 details the slide switches factory settings and their functions.

Figure 6.1 shows the position and meaning of the slide switches.

Note: Using the PTC input for cut-off (stopping) function does not fulfill EN81-20/50.

7. Encoder option boards

Encoder boards connect to port C and are selected via parameter L01. Table 7.1 shows L01 settings and related option boards.

7.1 OPC-PG3

The OPC-PG3 board is for HTL standard encoders. Table 7.2 lists the technical requirements.

Table 7.3 and Figure 7.2 describe the wiring for this encoder type.

7.2 OPC-PMPG

The OPC-PMPG board is for line driver standard encoders (5 VDC differential signals). Table 7.4 lists the technical requirements.

Table 7.5 and Figure 7.3 describe the wiring for this encoder type.

7.3 OPC-PR

The OPC-PR board is for sin/cos encoders (sinusoidal wave for incremental and absolute signals). Table 7.6 lists the technical requirements.

Table 7.7 and Figure 7.4 describe the wiring for this encoder type.

7.4 OPC-PSH

The OPC-PSH board is for serial absolute encoders (sinusoidal wave for incremental signals and serial communications for absolute signals). Table 7.8 lists the technical requirements.

Table 7.9 and Figure 7.5 describe the wiring for this encoder type.

Table 7.10 provides specific settings for BiSS, SSI, and Hiperface encoders.

8. Keypad operation

8.1 TP-E1U (Basic keypad)

8.1.1 Led monitor, keys and LED indicators on the keypad

The keypad has a four-digit LED monitor, six keys, and five LED indicators. It allows monitoring of running status, function code data, I/O signals, maintenance information, and alarm information.

Figure 8.1 provides a keypad overview. Table 8.1 explains the keypad functions.

8.1.2 Overview of operation modes

The TP-E1U keypad operates in three modes: Running mode, Programming mode, and Alarm mode. Figure 8.2 illustrates the status transitions between these modes.

Simultaneous keying: Pressing two keys at the same time is expressed with a "+" between the keys (e.g., PRG + RESET).

8.1.3 USB connectivity

The keypad has a USB port (Mini-B connector) on the front for PC connection.

Refer to the FRENIC Loader Instruction Manual for instructions on using FRENIC Loader 4.

8.1.4 TP-E1U Menu

The partial menu list can be accessed by pressing PRG + RESET. To access all menus, set E52=2.

• 0. Quick Setup (0.Fnc): Displays basic function codes for customization.
• 1. Data Setting (From 1.F__ to 1.K__): Allows display/change of function codes.
• 2. Data Checking (2.rEP): Displays function codes changed from factory defaults.

3. Drive Monitoring (3.0PE): Displays running information for maintenance or testing.

4. I/O Checking (4.1_0): Displays external interface information.

5. Maintenance Information (5.CHE): Displays maintenance information, including cumulative run time.

6. Alarm Information (6.AL): Displays the last four alarm codes and related running information.

7. Data Copying (7.CPY): Allows reading, writing, and verifying function code data.

Figure 8.4 illustrates the function setting procedure.

8.2 TP-A1-LM2 (Advanced keypad)

8.2.1 Keypad keys

The TP-A1-LM2 keypad allows users to run/stop the motor locally, monitor status, set function codes, and monitor I/O signals, maintenance, and alarm information.

Figure 8.5 shows the keypad components. Table 8.3 provides a keypad overview. Table 8.4 explains LED indicator functions. Table 8.5 outlines keypad functions.

8.2.2 Keypad menus

Table 8.6 details the keypad menu organization and functions.

8.2.3 Example of function setting

This section explains how to set function code data, using the example of changing "F03: Rated speed" from 1450 r/min to 1800 r/min.

Figure 8.6 shows the screen transition example.

8.2.4 Display language setting

Display language can be selected via the "Language" sub-menu (Menu 1. Start-up). Access the Program menu by pressing PRG, select the menu using arrow keys, and validate with SET. Alternatively, parameter K01 can be used.

Table 8.5 lists available languages and their corresponding numbers.

9. Driving the motor

9.1 Inverter initialization

Inverters can be programmed with different pre-settings based on the application type. Initialization requires a double-key operation (e.g., STOP key and another key). Table 9.1 lists available initialization types and their functions.

9.2 Specific setting for induction motors

Motor parameters (e.g., poles, rated speed, voltage, current) must be set manually according to the motor's nameplate. Table 9.2 shows the basic settings required. Parameters must be set in the specified order to avoid malfunctions.

9.3 Auto tuning procedure (for IM)

After inverter initialization and motor parameter setting, perform auto tuning. This procedure obtains motor data like no-load current, stator resistance, stator inductance, and slip frequency.

Follow these steps:

1. Set functions as described in Tables 9.1 and 9.2.
2. Set function P04 to 3 and press SET.
3. Give a RUN command from the lift controller (e.g., INSPECTION mode). Keep the RUN command until the inverter indicates completion. Main contactors will close, and current will flow through the motor, producing acoustic noise. This procedure takes seconds.

If the inverter trips Er7 during the procedure, verify settings in Tables 9.1 and 9.2 and the connections recommended in Chapter 5. For IM closed-loop control, if no-load current is too high, try auto tuning mode 2 (P04=2).

After auto tuning, give a RUN command and check motor operation and output current.

For closed-loop control (motor with encoder), if the inverter trips OC, OS, or ErE after giving RUN command, set H190=0 (swaps two motor phases).

9.4 Specific setting for PMS motors

Motor parameters for synchronous motors (PMSM) must be set manually. Table 9.3 shows the basic settings required. Parameters must be set in the specified order to avoid malfunctions.

9.5 Pole tuning procedure (for PMS motors)

After initialization and motor parameter setting, perform pole tuning to obtain the encoder offset and set parameter L04.

Follow these steps:

1. Set functions as described in Tables 9.1 and 9.2.
2. Set function L03 to 4 and press SET.
3. Give a RUN command from the lift controller (e.g., INSPECTION mode). Keep the RUN command until completion. Main contactors will close, and current will flow through the motor, producing acoustic noise. This procedure takes seconds.
4. After completion, the offset value is saved and shown in function L04. Record this value.
5. If possible, open the brake and let the cabin move slightly.
6. Repeat steps 3 and 4. The result in L04 should not differ by more than ±15° between measurements.

If the difference is more than ±15°, set H190=0. If the inverter trips OC, OS, or ErE, set H190=0. If Er7 occurs, verify settings in Tables 9.1 and 9.2 and connections from Chapter 5.

After tuning, give a RUN command and check motor operation and output current.

10. Setting the speed profile

Setting the speed profile includes:

• Travelling speed
• Acceleration and deceleration times (s)
• S curves (%)

Acceleration, deceleration times, and S curves can be set independently for rated speed, intermediate speeds, and creep speed. These times refer to maximum speed (F03).

Table 10.1 shows available acceleration/deceleration ramps and S-curves. It indicates the ramps used for acceleration/deceleration between speeds. The "AFTER CHANGE" column shows the target speed, and the "BEFORE CHANGE" row shows the initial speed.

Table 10.2 provides guidelines for acceleration, deceleration times, and deceleration distances for different travelling speeds.

11. Signals time diagram for close loop control (IM and PMSM)

Figure 11.1 shows a time diagram and signal sequence for closed-loop applications, illustrating a standard lift travel with digital inputs for high and creep speed. Induction and PMS motors are equivalent in this case.

The diagram details signals like EN, FWD/REV, speed selection inputs (X1, X2, X3), magnetic contactor (Y4), mechanical brake (Y5), and torque current.

Sequence description:

• Start: Activating FWD/REV and EN1/EN2 terminals initiates timers. High speed is selected by X1, X2, X3. When timer L85 elapses, the inverter activates IGBT gates.
• After time L82, the brake control output activates, and the mechanical brake releases after time t2. After time F24, the speed set point is used, and the lift accelerates to high speed.
• Stop: Terminal X3 deactivates to decelerate to creep speed. Creep speed deactivates when the floor level is reached (FWD/REV, X1, X2 deactivated).
• After deceleration, the motor reaches zero speed (F25). Timer H67 starts, and after time L83, the brake output deactivates, applying the brake after time t3.
• The EN signal must remain active until no current flows from the inverter to the motor (when timer F22 elapses).

Figure 11.1 assumes the inverter controls brake and main contactor signals. If the lift controller manages these signals, timing may differ.

Speeds, acceleration/deceleration ramps, and S-curves depend on the signal sequence (EN, FWD/REV, X1, X2, X3).

12. Signal time diagram for open loop (IM)

Figure 12.1 shows a time diagram and signal sequence for open-loop applications, illustrating standard lift travel with digital inputs for high and creep speed. Only induction motors can be controlled in open loop.

The diagram details signals like EN, FWD/REV, speed selection inputs (X1, X2, X3), magnetic contactor (Y4), mechanical brake (Y5), and output current.

Sequence description: Similar to closed-loop, with variations in stop sequence (F20, F22, F25).

Figure 12.1 assumes the inverter controls brake and main contactor signals. If the lift controller manages these signals, timing may differ.

Speeds, acceleration/deceleration ramps, and S-curves depend on the signal sequence (EN, FWD/REV, X1, X2, X3).

13. Travel optimization in closed loop

The default inverter settings are generally suitable for most lifts. However, adjustments may be needed for better performance (lift comfort) due to mechanical construction, friction, or motor behavior. These adjustments involve control loops: ASR (Automatic Speed Regulator), APR (Automatic Position Regulator), and ACR (Automatic Current Regulator).

Figure 13.1 shows the phases of standard lift travel and the active control loop during each phase.

Notes:

• When L76=0, L05 is the gain for the ACR loop for ULC.
• If soft start (H64, H65) is used, ULC is active during H64. ASR at low speed is active during F24. Refer to RM for soft start details.
• L05 can be obtained via Auto tuning (P04=4). Refer to Chapter 9.3 for details.

14. Lift fine tuning (troubleshooting)

Typical problems are divided into three zones: starting, travel, and stopping. Figure 14.1 illustrates these zones.

14.1 Open loop control (IM)

TROUBLESHOOTING (Starting)

TROUBLESHOOTING (Travel)

TROUBLESHOOTING (Stopping)

14.2 Closed loop control (PMSM and IM)

TROUBLESHOOTING (Starting)

15. Alarm messages

Table 15.1 lists alarm messages, their descriptions, and possible causes.