Instruction Manual

OPC-LM1-PR

Option Card for Permanent

Magnet Synchronous Motor
Drive

CAUTION
■ Deliver this instruction manual without fail to
those who actually operate the equipment.

■ Read this instruction manual and

understand the description before installing,
connecting (wiring), operating or performing
maintenance and inspection of the option.

■ Keep this instruction manual in a safe place

until the option is discarded.

■ The product is subject to change without

prior notice.

Fuji Electric FA Components & Systems Co., Ltd. INR-SI47-1181-E

Preface
Thank you for purchasing our OPC-LM1-PR inverter option card. Before using the option card, read this manual carefully
to understand how to use the option card correctly. Improper handling blocks correct operation or causes a short life or
breakdown. This manual does not describe how to use the inverter. Refer to the FRENIC-Lift Instruction Manual for details
about the inverter. Keep this manual on hand for reference when using the option card.

Safely Precautions
Note the following items when using the option card. Improper use may result in unexpected failure, electric shock, or
possible injury.

(1) Application
WARNING
•This product must not be used for any life support system or other purpose directly related to human safety.
•Although this product is manufactured under strict quality control, be sure to install appropriate safety devices for
applications where drive failure could result in serious accident or material loss.
An accident could occur.

(2) Installation and Wiring

WARNING
• Wait at least five minutes after turning off the power before installing or wiring the option card.
Use a circuit tester or similar instrument to check the voltage before performing installation or wiring.
(Check whether the charge lamp goes off.) Otherwise, electric shock may occur.
• Discharge statistic electricity from your body before handling the option card. Never touch the
option card with wet hands; otherwise, accident or electric shock may occur.
• No foreign matter such as screws, metal patches, lint, chips, and dust in the option card.
There is risk of fire or accident.
• Do not damage or stress the wiring; otherwise, accident or electric shock may occur.
• Do not connect the reducer between the motor and the encoder.
There is a risk of accident.

CAUTION
• Do not install or operate a damaged option card or one that is lacking parts; otherwise, an injury may occur.
• Since noise is generated by the inverter, motor, and wiring, carefully monitor surrounding sensors
and devices for abnormal operation. There is a risk of accident.

(3) Operation
WARNING
• Check and adjust parameters before operation. Improper parameters may cause an unexpected
action for some machines. There is a risk of accident.

CAUTION
• High-speed operation can be set easily for the inverter. Fully check motor or device performance
before changing the setup; otherwise, accident may occur.

(4) Maintenance and Inspection, and Parts Replacement

WARNING
• Wait at least five minutes after turning off the power before inspecting the option card. (Check whether the
charge lamp goes off.) There is a risk of electric shock.
Only authorized personnel are allowed to maintain and inspect the option card and replace
parts; otherwise, electric shock or injury may occur.
• Never modify the option card; otherwise, electric shock or injury may occur.

CAUTION
• Do not execute a megger test (insulation resistance measurement).

(5) Discard
CAUTION
• Since the option card uses soldering lead, treat it as an industrial waste when discarding it.

1
 Contents
Page
1. General Information............................................................................................................................... 3
1.1. Introduction to OPC-LM1-PR .......................................................................................................... 3
1.2. Before Using the Option Card......................................................................................................... 3
1.3. Accessories..................................................................................................................................... 3
1.4. Installation Procedure ..................................................................................................................... 4
1.5. Product Guarantee ......................................................................................................................... 5
2. Specifications ........................................................................................................................................ 5
2.1. Storage Environment ...................................................................................................................... 5
2.1.1. Temporary Storage ................................................................................................................... 5
2.1.2. Long-term Storage ................................................................................................................... 5
2.2. Operating Environment ................................................................................................................... 6
2.3. Terminal Arrangement..................................................................................................................... 6
2.4. Terminal Function and Specifications.............................................................................................. 7
2.5. Control Specifications ..................................................................................................................... 7
3. Applicable Encoder................................................................................................................................ 8
3.1. Specifications of Applicable Encoder .............................................................................................. 8
3.2. Encoder Installation and Signal ...................................................................................................... 8
4. Wiring .................................................................................................................................................... 9
4.1. Wiring Length and Cable Size ........................................................................................................ 9
4.2. Plug................................................................................................................................................. 9
4.3. Basic Wiring Diagram ................................................................................................................... 10
5. Function............................................................................................................................................... 11
5.1. Function Code Setting .................................................................................................................. 11
5.2. Procedure of Magnetic Pole Position Offset Tuning...................................................................... 11

If anything is unclear about the option card or there is something doubtful about its condition,
contact your distributor or your nearest branch office.

2
1 General Information
1.1 Introduction to OPC-LM1-PR
This product is an encoder interface card to be installed in the Fuji inverter FRENIC-Lift. It enables vector control according
to feedback signals from the HEIDENHAIN rotary encoder (ERN1387).

1.2 Before Using the Option Card

Check the following items when you receive this product. Also check whether this product has been damaged during
transport. If anything is amiss, contact your distributor or your nearest branch office.

(1) The option card is contained in the package.

(2) The option card is not damaged during transportation--no defective electronic devices, dents or warps.
(3) The model name "OPC-LM1-PR" is printed on the option card. (See Figure 1.1.)

Front View Side View

Nameplate

Connector
CN1

Model name
Option PC Board
OPC-LM1-PR

Terminal Block
TERM1

Figure 1.1 Product Appearance.

Nameplate

01 7 5 1

Production week in the month (1 to 6)

Production month
(1 to 9：January to September, X：October, Y：November, Z：December)

Production year：Last digit of year (7 ⇒2007)

Production lot serial number

Figure 1.2 Nameplate

1.3 Accessories
Confirm that the following accessories are included in the package:
1. Instruction Manual ･･････････ 1
2. Accessories 1) Plug for TERM1 ･･････････ 1

3
1.4 Installation Procedure

WARNING
• Turn off the power and wait for at least five minutes before starting installation. Further, check that the LED monitor is
unlit and check that the DC link bus voltage between the P (+) and N (-) terminals is lower than 25 VDC.
Otherwise, electric shock could occur.

Top Cover

Option Card
OPC-LM1-PR

4 spacers

CN1

4 spacer holes

Connecter(CN1)

Control circuit board Make sure there is no idle gap

between the spacers and the
printed circuit board and
OPC-LM1-PR card.
(Altogether 8 places)
【STEP1】
Remove the top-cover from the inverter.

【STEP2】 Option Card

Insert the four spacers and CN1 on the back OPC-LM1-PR
of the OPC-LM1-PR into the spacer holes and
connector (CN1) on the control circuit
board in the inverter. Option Terminal Block
Visually check that the spacers and CN1 are
firmly inserted.

【STEP3】
Wire on OPC-LM1-PR.

【STEP4】
Put the top-cover back to the inverter.
Figure 1.3 Installation Drawing
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1.5 Product Guarantee
The product guarantee term is one year after installation or two years after manufacturing on the nameplate, whichever
expires first.
However, the guarantee will not apply in the following cases, even if the guarantee term has not expired.

(1) The cause includes incorrect usage or inappropriate repair or modification.

(2) The product is used outside the standard specified range.
(3) The failure is caused by dropping, damage or breakage during transportation after the purchase.
(4) The cause is earthquake, fire, storm or flood, lightening, excessive voltage, or other types of disaster or secondary
disasters.

2 Specifications
2.1 Storage Environment
2.1.1 Temporary Storage
Store the option card in an environment that satisfies the requirements listed in Table 2.1.
Table 2.1 Environmental Requirements for Storage and Transportation
Item Requirements

Storage -25 to 70°C

Temperature *1 Location where the option card is not subject to abrupt changes in
temperature that would result in the formation of condensation or ice.
Relative *2
5 to 95%
humidity
The inverter must not be exposed to dust, direct sunlight, corrosive or flammable gases, oil mist,
Atmosphere vapor, water drops or vibration. The atmosphere must contain only a low level of salt.
(0.01 mg/cm2 or less per year)
Atmospheric 86 to 106 kPa (in storage)
pressure 70 to 106 kPa (during transportation)
*1
Assuming a comparatively short storage period (e.g., during transportation or the like)
*2
Even if the humidity is within the specified requirements, avoid such places where the option card will be subjected to
sudden changes in temperature that will cause condensation to form.

Precautions for temporary storage

(1) Do not leave the inverter directly on the floor.
(2) If the environment does not satisfy the specified requirements, wrap the option card in an airtight vinyl sheet or the like
for storage.
(3) If the option card is to be stored in an environment with a high level of humidity, put a drying agent (such as silica gel) in
the airtight package described in item (2).
2.1.2 Long-term Storage
The long-term storage methods for the inverter vary largely according to the environment of the storage site. General
storage methods are described below.
(1) The storage site must satisfy the requirements specified for temporary storage.
(2) The inverter must be stored in a package that is airtight to protect it from moisture. Include a drying agent inside the
package to maintain the relative humidity inside the package to within 70%.
(3) If the option card has been installed in the equipment or control board at a construction site where it may be subjected to
humidity, dust or dirt, then remove the option card and store it in a suitable environment specified in Table 2.1.

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2.2 Operating Environment
Install the inverter in an environment that satisfies the requirements listed in Table 2.2.
Table 2.2 Environment Requirements
Item Specifications
Location Indoors

Ambient -10 to 45°C

temperature

Relative
5 to 95% (No condensation)
humidity
The option card must not be exposed to dust, direct sunlight, corrosive gases, flammable
gas, oil mist, vapor or water drops.
2
Atmosphere The atmosphere must contain only a low level of salt. (0.01 mg/cm or less per year)
The inverter must not be subjected to sudden changes in temperature that will cause
condensation to form.
Altitude 1,000 m max. (Note)
Vibration 3 mm (Max. amplitude)：2 to 9 Hz, 9.8 m/s2：9 to 20 Hz, 2 m/s2：20 to 55 Hz
1 m/s2：55 to 200 Hz

(Note) If you use the inverter in an altitude above 1000 m, you should apply an output current derating factor as listed in
Table 2.3.

Table 2.3 Output Current Derating Factor in Relation to Altitude

Altitude Output current derating factor
1000 m or lower 1.00
1000 to 1500 m 0.97
1500 to 2000 m 0.95
2000 to 2500 m 0.91

2500 to 3000 m 0.88

2.3 Terminal Arrangement

PO PO CM CM CM PA+ PA- PB+ PB- PC+ PC- PD+ PD- FPA FPB CM

TERM1

Figure 2.1 Terminal Arrangement

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2.4 Terminal Function and Specifications

Table 2.4 Terminal Function and Electrical Specifications of OPC-LM1-PR

Abbreviation Terminal name Terminal function Electric specifications
Power supply for Terminal which supplies ・5 VDC±5%, Max. 300 mA
PO
encoder power for encoder ・5 VDC±5% Allowable wiring length.
Common terminal of 0 to 10 m：One wire each for PO and CM line
CM 0 to 20 m：Two wire each for PO and CM line
power supply
The A phase input The A phase input the ・Input frequency
PA+
terminal (non-inverting) amplitude and the Max. 50 kHz
frequency change ・Differential input signal：
The A phase input depending on the speed of
PA- PA(+) - PA(-), PB(+) - PB(-)
terminal (inverting) the motor.
The B phase input The B phase input the
PB+
terminal (non-inverting) amplitude and the 0.6V to 1.2V
frequency change
The B phase input depending on the speed of
PB-
terminal (inverting) the motor.
The C phase input The C phase input the
PC+ ・Input frequency
terminal (non-inverting) amplitude and the
frequency change Max. 24.4 Hz
The C phase input depending on the speed of ・Differential input signal：
PC-
terminal(inverting) the motor. PC(+) - PC(-), PD(+) - PD(-)
The D phase input The D phase input the
PD+
terminal (non-inverting) amplitude and the
frequency change 0.6V to 1.2V
The D phase input depending on the speed of
PD-
terminal(inverting) the motor.
The pulses with same ・Transistor output (Open collector)
The A phase pulse frequency as the A phase ・Operation voltage of OFF level : Max. 27 V
FPA
output input are output. ・Operation voltage of ON level : Max. 2.0 V
・Load current at ON : Max. 50 mA
The pulses with same
The B phase pulse ・Leakage current at OFF : Max. 200µA
FPB frequency as the B phase
output input are output

(Note) It is recommended that terminals FPA and FPB are pulled up with lowest value of resistor with the sink current not
exceeding 50 mA when terminals FPA and FPB are used.

2.5 Control Specifications

Table 2.5 Control Specifications
Item Control Specifications Remarks
Motor control method Vector control -
Speed control range 0 r/min to 1500 r/min -

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3 Applicable Encoder
CAUTION
• Check the encoder specification again before operating the inverter. Improper encoder specification may cause
unexpected inverter operation or device operation.
There is a risk of accident or injury.

3.1 Specifications of Applicable Encoder

Table 3.1 Specifications of Applicable Encoder

Item Specifications
2 sinusoidal signals A and B as sine and cosine with 2048 periods per
Incremental signals
revolution
Application Rotor Position Detection 2 sinusoidal signals C and D as sine and cosine with one period per revolution
encoder
Encoder power supply +5 VDC (5 VDC ±5%/300 mA)
Encoder model HEIDENHAIN ERN1387 or its equivalent

3.2 Encoder Installation and Signal

The encoder shall rotate in the direction shown in Figure 3.1 when terminal FWD is ON.
Encoder output pulse is shown in Figure 3.2. Connect the encoder directly to the motor using a coupling.
If the encoder rotation is different from that shown in Figure 3.1, interchange V with W of inverter output.
The rotational direction of IEC standard motors is opposite to that shown in Figure 3.1.

Rotational direction when terminal FWD is ON.

Driving side

Encoder
Motor

Figure 3.1 Motor and Encoder Rotational Direction when Terminal FWD is ON

FWD ON REV ON

PA+,PA-Differential
input signal

PB+,PB-Differential
input signal

FPA

FPB

Figure 3.2 Definition of Terminal FWD ON/REV ON

8
4 Wiring
CAUTION
• Check the wiring again before operating the inverter. Improper wiring may cause unexpected inverter operation or
device operation.
There is a risk of accident or injury.

4.1 Wiring Length and Cable Size

Table 4.1 Maximum Wiring Length
Item Specifications
Maximum wiring length between option card and encoder 20 m
Maximum wiring length between option card (terminals FPA and FPB) and user controller 5m

Wiring for the encoder option card and encoder

2
The encoder connection cable must use cable made by HEIDENHAIN 17 pin (4 x 0.14) +4(2 x 0.14) + (4 x 0.5) mm .
2
Connect 0.5 mm with PO and terminal CM of the option card.

Table 4.2 Terminal Wiring of OPC-LM1-PR

Terminal
Wiring color Encoder side symbol Note
name
blown / green 5V Up
PO
blue 5V sensor Connect when the wiring length is 10 m or more.
white / green 0V Un
CM
white 0V sensor Connect when the wiring length is 10 m or more.
PA+ green / black A+
PA- yellow / black A-
PB+ blue / black B+
PB- red / black B-
PC+ gray C+
PC- pink C-
PD+ Yellow D+
PD- purple D-

Wiring of the option card and the encoder

• The wiring of the option card and encoder must use the shield wire. Moreover, the cable length is 20 m or less.
• Connect shield of the wire to terminal CM of this option card.
• Separate the wiring of the option card and the wiring of other power lines to prevent the malfunction by the noise.
Never put them in the same duct.

4.2 Plug
Applicable terminal plugs
The terminal block for encoder connection is removable type.
The plug (electric wire connection side) is provided as an accessory of the option card.

Table 4.3 Applicable Plug Model

Terminal Block Terminal Plugs Type Manufacturer
TERM1 MC1.5/16-STF-3.81 Phoenix Contact

Plug specifications
Table 4.4 Plug Specifications
Item Specifications
Tightening torque 0.22 to 0.25 N・m
Screw size M2
Bared wire length 7 mm
Maximum wire size AWG16

(Note) Insert the wire into the upper side of the metal bracket on the terminal block, and tighten the screw.
9
 M2

7(mm)

Connection of Wiring on Option

Terminal Side.

4.3 Basic Wiring Diagram

CAUTION
• Keep the power supply voltage of encoder in the specification voltage of encoder.
There is a risk of failure.

L1/R U
L2/S V M
L3/T W
FRN-LM1S
G

OPC-LM1-PR

PO
PO
PA+
PA-
PB+
PB-
PC+
PC- Encoder
PD+
PD-
CM
CM
CM

FPA
FPB
User
CM Controller

Figure 4.1 Basic Wiring Diagram

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5 Function
5.1 Function Code Setting
CAUTION
• Set the function code in the following order at first.
(1) C21 (2) P01 (3) F03 (4) L31 (5)P02
Because when you change them, some other function codes synchronize and change.
There is a risk of accident or injury.

Set the function code as follows before beginning magnetic pole position offset tuning.

Code Name Data Setting

C21 Unit for Speed Command Your easy-to-use setting
P01 Motor - Number of poles Depends on the motor
F03 Maximum Speed Depends on the motor
L31 Elevator Parameter - Speed Depends on the elevator
P02 Motor - Rated capacity Depends on the motor

Code Name Data Setting

F04 Rated Speed Depends on the motor
F05 Rated Voltage at Rated Speed Depends on the motor
F42 Control Mode 1 (PM motor - Vector control with encoder)
P03 Motor - Rated current Depends on the motor
P07 Motor - %R1 5.0 (%)
P08 Motor - %X 10.0 (%)
L01 Pulse encoder - System 5
L02 Pulse encoder - Resolution Depends on the encoder
L36 ASR - P - Constant at high speed 2.0 (It is necessary to adjust)
L38 ASR - P - Constant at low speed 2.0 (It is necessary to adjust)

5.2 Procedure of Magnetic Pole Position Offset Tuning

You have to execute the tuning as follows before driving motor.
Please inquire of the maker if tuning is impossible normally.

1. Tuning Mode (Function code L03)

Tuning mode is selected by function code L03 as follows. Usually, it is selected according to the tuning procedure.
1 : Tuning operation
2 : Tuning operation with wrong wiring detection (Er7 occurs if wrong wiring is detected.)
3 : Tuning operation with checking accuracy (Er7 occurs if tuning accuracy is not good.)
4 : Reserved for particular manufactures (Do not access this function code.)
5 : Reserved for particular manufactures (Do not access this function code.)

2. Tuning Condition
The recommended condition is following.

(1) The rotor is fixed.

If it is impossible to fix the rotor, it is acceptable even if the rotor is free. (In this case, if the torque bias has been
set, cancel it.)

(2) Encoder abnormality detection is effective. (It is effective in the initial condition as follows. L90=1, L91=10%,
L92=0.5)

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3. Tuning procedure

(1) Apply the brakes and fix the rotor. It is acceptable without the brake in the case of the tuning at the motor unit.
(2) Confirm the motor is connected with the inverter.
(3) If you use Multi Function Key Pad (MFKP), we recommend local mode. Keep pushing the "REM/LOC" key of
MFKP until the indicator “REM” change into “LOC”.

(4) Execute the tuning with the function code L03=2 (*1). This work is used to detect the wrong wiring.
However, in the case of Surface Permanent Magnet motor (SPM motor), this work cannot detect the wrong
wiring. In this case, skip to procedure 3-(5).

In the case of finishing tuning normally, Skip to procedure 3-(5).

If tuning error (Er7) occurs, it might be wrong wiring. Reset the error display and execute the procedure as
follows.
After turning off the power supply, replace V and W of the wiring for inverter drive, and execute the tuning again
afterwards.
(In the case of the rotor free, if tuning error (Er7) occurs similarly even if V and W are replaced, it might be
disconnection or wrong wiring of the encoder. Try to wire correctly, and execute again from the beginning.)

(5) Execute the tuning with the function code L03=3. (Note 1)

The tuning procedure is completed.

(Note 1) Tuning procedure after reactivates

- In the case of local mode
Select "1 DATA SET" in the program mode of MFKP, change the function code L03, and set with the
“FUNC/DATA” key. Pressing the “FWD” key starts tuning. The "EXECUTING" is displayed on the monitor of the
MFKP during the tuning.
The "EXECUTING" disappears, indicating that it is the end of tuning. The L03 data automatically returns to "0".
The tuning result is stored in the function code L04. Check the result and make the note of the value.
- In the case of remote mode
Set the function code L03. When the drive instruction is set, the tuning is begun.
In the tuning mode (L03=1 or 3), tuning takes 4 seconds. In the tuning mode (L03=2), tuning takes 24 seconds.
Release the drive instruction after the regulated time has elapsed. The L03 data returns to "0." The tuning result is
stored in the function code L04. Check the result and make the note of the value.

4. Checking that tuning is completed normally

In the normal mode, run the motor.

The recommended checking procedure is given below.
Make the motor rotate more than one rotation at the low frequency about 1 Hz.
In the MFKP local mode, do the following:
1) Push the "FWD" key and set the reference speed at about 1 Hz.
2) Make the motor rotate more than one rotation.
3) Push the "STOP" key. When the motor stops, the reference speed returns to 0.

If the motor does not rotate normally, do the following:

1) Check that the function codes are properly configured.
2) Check the wiring between the encoder and option card.
3) Match the rotational direction of the motor with that of the encoder.
If any problem is found in steps 1) to 3) above, correct it (them) and perform tuning again.
If no problem is found, change the motor-inverter wiring between V and W and then perform tuning again.

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