FR-A500 HIGH FUNCTION ACOUSTIC NOISE FR-A520-0.4K 55K(-NA) F
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TRANSISTORIZED INVERTER
FR-A500
HIGH FUNCTION ACOUSTIC NOISE
FR-A520-0.4K 55K(-NA) FR-A540-0.4K 55K(-NA)(-EC)
INSTRUCTION MANUAL
Thank choosing this Mitsubishi transistorized Inverter. This instruction manual gives handling information precautions this equipment. Incorrect handling might cause unexpected fault. Before using inverter, please read this manual carefully equipment optimum. Please forward this manual user. This section specifically about safety matters
attempt install, operate, maintain inspect inverter until have read through this instruction manual appended documents carefully equipment correctly. inverter until have full knowledge equipment, safety information instructions. this instruction manual, safety instruction levels classified into "WARNING" "CAUTION".
WARNING CAUTION
Assumes that incorrect handling cause hazardous conditions, resulting death severe injury. Assumes that incorrect handling cause hazardous conditions, resulting medium slight injury, cause physical damage only.
Note that CAUTION level lead serious consequence according conditions. Please follow instructions both levels because they important personnel safety.
SAFETY INSTRUCTIONS Electric Shock Prevention
WARNING
While power when inverter running, open front cover. electric shock. inverter with front cover removed. Otherwise, access exposed highvoltage terminals charging part circuitry electric shock. power off, remove front cover except wiring periodic inspection. access charged inverter circuits electric shock. Before starting wiring inspection, switch power off, wait more least minutes check presence residual voltage with meter (check chapter further details.) etc. class (200V) special class (400V) higher earthing method earth inverter. person involved wiring inspection this equipment should fully competent work. Always install inverter before wiring. Otherwise, electric shock injured. Operate switches with hands prevent electric shock. subject cables scratches, excessive stress, heavy loads pinching. Otherwise, electric shock. change cooling while power will invite hazardous condition.
Fire Prevention
CAUTION
Mount inverter incombustible surface. Installing inverter directly near combustible surface could lead fire. inverter become faulty, switch inverter power. continuous flow large current could cause fire. connect resistor directly terminals This could cause fire.
Injury Prevention
CAUTION
Apply only voltage specified instruction manual each terminal prevent damage etc. Ensure that cables connected correct terminals. Otherwise, damage etc. occur. Always make sure that polarity correct prevent damage etc. After inverter been operating relativly long period time, touch inverter burnt.
Additional instructions
Also note following points prevent accidental failure, injury, electric shock, etc.:
Transportation installation
CAUTION
When carrying products, correct lifting gear prevent injury. stack inverter boxes higher than number recommended. Ensure that installation position material withstand weight inverter. Install according information Instruction Manual. operate inverter damaged parts missing. hold inverter front cover; fall off. stand rest heavy objects inverter. Check inverter mounting orientation correct. Prevent screws, wire fragments, conductive bodies, other flammable substances from entering inverter. drop inverter, subject impact. inverter under following environmental conditions:
Constant torque: -10°C +50°C (14°F 122°F) (non-freezing) (-10°C +40°C with FR-A5CV attachment) Ambient temperature Variable torque: -10°C +40°C (14°F 104°F) (non-freezing) (-10°C +30°C with FR-A5CV attachment) Ambient humidity 90%RH less (non-condensing) Storage temperature -20°C +65°C* (-4°F 149°F) Ambience Indoors (free from corrosive gas, flammable gas, mist, dust dirt) Maximum 1000m (3280.80 feet.) above level standard operation. Altitude, vibration After that derate every extra 500m 2500m (91%). applicable short time, e.g. transit.
Wiring
Environment
CAUTION
capacitive equipment such power factor correction capacitor, noise filter surge suppressor output inverter. connection orientation output cables motor will affect direction rotation motor.
Trial
CAUTION
Check parameters, ensure that machine will damaged sudden start-up.
Operation
CAUTION
When have chosen retry function, stay away from equipment will restart suddenly after alarm stop. [STOP] valid only when appropriate function setting been made. Prepare emergency stop switch separately. Make sure that start signal before resetting inverter alarm. failure restart motor suddenly.
CAUTION
load used should three-phase induction motor only. Connection other electrical equipment inverter output damage equipment. electronic overcurrent protection does guarantee protection motor from overheating. magnetic contactor inverter input frequent starting/stopping inverter. noise filter reduce effect electromagnetic interference. Otherwise nearby electronic equipment affected. Take measures suppress harmonics. Otherwise power harmonics from inverter heat/damage power capacitor generator. When 400V class motor inverter-driven, should insulation-enhanced surge voltages suppressed. Surge voltages attributable wiring constants occur motor terminals, deteriorating insulation motor. When parameter clear clear performed, each parameter returns factory setting. Re-set required parameters before starting operation. inverter easily high-speed operation. Before changing setting, examine performance motor machine. addition inverter's holding function, install holding device ensure safety. Before running inverter which been stored long period, always perform inspection test operation.
Emergency stop
CAUTION
Provide safety backup such emergency brake which will prevent machine equipment from hazardous conditions inverter fails.
Maintenance, inspection parts replacement
CAUTION
carry megger (insulation resistance) test control circuit inverter.
Disposing inverter
CAUTION
Treat industrial waste.
General instructions
Many diagrams drawings this instruction manual show inverter without cover, partially open. Never inverter like this. Always replace cover follow this instruction manual when operating inverter.
CONTENTS
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Pre-Operation Information 1.1.1 Precautions operation.1 Basic Configuration.2 1.2.1 Basic configuration Structure 1.3.1 Appearance structure 1.3.2 Removal reinstallation front cover 1.3.3 Removal reinstallation operation panel.6
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Installation.7 2.1.1 Instructions installation Wiring 2.2.1 Terminal connection diagram 2.2.2 Wiring main circuit 2.2.3 Wiring control circuit 2.2.4 Connection connector.22 2.2.5 Connection stand-alone option units 2.2.6 Design information.28 Other wiring 2.3.1 Power harmonics 2.3.2 Japanese harmonic suppression guidelines.30 2.3.3 Inverter-generated noises reduction techniques.33 2.3.4 Leakage currents countermeasures 2.3.5 Inverter-driven 400V class motor 2.3.6 Peripheral devices 2.3.7 Instructions compliance with standards 2.3.8 Instructions compliance with European standards 2.3.9 Earthing version).43
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Pre-Operation Information 3.1.1 Devices parts prepared operation 3.1.2 Power on.47 3.1.3 Parameter check.47 Operation 3.2.1 Pre-operation checks.53 3.2.2 External operation mode (Operation using external input signals) 3.2.3 operation mode (Operation using operation panel (FR-DU04)).55 3.2.4 Combined operation mode (Operation using external input signals
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Parameter List Parameter Function Details
Torque boost (Pr. 112) Output frequency range (Pr.
Base frequency, base frequency voltage (Pr. 113).65 Multi-speed operation (Pr. 239) Acceleration/deceleration time (Pr. 110, 111) Electronic overcurrent protection (Pr. 9).68 dynamic brake (Pr. 12).69 Starting frequency (Pr. Load pattern selection (Pr. operation (Pr. input selection (Pr. Stall prevention (Pr. 148, 149, 154).73 Multi-speed input compensation (Pr. 28).74 Acceleration/deceleration pattern (Pr. 143).75 Regenerative brake duty (Pr. 70).76 Frequency jump (Pr. Speed display (Pr. 144) Up-to-frequency sensitivity (Pr. Output frequency detection (Pr. 116) Second/third stall prevention (Pr. 114, 115) Monitor display/FM, terminal function selection (Pr. 158) Monitoring reference (Pr. 56).84 Automatic restart after instantaneous power failure (Pr. 165) Remote setting function selection (Pr. Intelligent mode selection (Pr. 60).88 Acceleration/deceleration reference current/lift mode starting frequency (Pr. 64). Retry function (Pr. Applied motor (Pr. carrier frequency (Pr. 240) Voltage input (Pr. Input filter time constant (Pr. Reset selection/PU disconnection detection/PU stop selection (Pr. Alarm code output selection (Pr. Parameter write inhibit selection (Pr. Reverse rotation prevention selection (Pr. .100 Operation mode selection (Pr. .101 Motor capacity/number motor poles/speed control gain (Pr. .104 Offline auto tuning function (Pr. .105 Online auto tuning selection (Pr. .111 control frequency (voltage) (Pr. 109).113 Computer link operation (Pr. 124).114 control (Pr. 134) .124 Commercial power supply-inverter switch-over function (Pr. 139). .131 Output current detection function (Pr. 150, 151).135 Zero current detection (Pr. 152, 153).136 signal activated condition selection (Pr. 155) .137 Stall prevention function current limit function (Pr. 156).137 signal output timer (Pr. 157) .139 User group selection (Pr. 160, 176) .140 Watt-hour meter clear/actual operation hour meter clear (Pr. 170, 171) .141 Input terminal function selection (Pr. 186) .141 Output terminal function selection (Pr. 195) .144
User initial value setting (Pr. 199) .146 Programmed operation function (Pr. 231) .147 Cooling operation selection (Pr. 244) .151 Stop selection (Pr. 250).152 Power failure-time deceleration-to-stop function (Pr. 266) .154 Stop-on-contact, load torque high-speed frequency selection (Pr. 270) .156 High-speed frequency control (Pr. 274).157 Stop contact (Pr. 275, 276).161 Brake sequence function (Pr. 285) .164 Droop control (Pr. 286, 287) .168 Meter (frequency meter) calibration (Pr. 900, 901) .169 Frequency setting voltage (current) bias gain (Pr. 905).171 Buzzer control (Pr. 990) .173
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Errors (alarms).174 5.1.1 Error (alarm) definitions .174 5.1.2 Correspondences between digital actual characters .177 5.1.3 Alarm code output.178 5.1.4 Resetting inverter.178 Troubleshooting .179 5.2.1 Checking operation panel display alarm stop .179 5.2.2 Faults check points .180 Precautions Maintenance Inspection.182 5.3.1 Precautions maintenance inspection.182 5.3.2 Check items .182 5.3.3 Periodic inspection.182 5.3.4 Insulation resistance test using megger .183 5.3.5 Pressure test.183 5.3.6 Replacement parts.186 5.3.7 Inverter replacement.187 5.3.8 Measurement main circuit voltages, currents power. .188
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Standard Specifications .190 6.1.1 Model specifications .190 6.1.2 Common specifications.192 6.1.3 Outline drawings .194
237,216
Option List.198 7.1.1 Stand-alone options.198 7.1.2 Inboard dedicated options .200
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Appendix Data Code List .201 Appendix List Parameters Classified Purposes Use.207 Appendix Operating Inverter Using Single-Phase Power Supply .208
CHAPTER OUTLINE
This chapter gives information basic "outline" this product. Always read instructions this chapter before using equipment.
Pre-Operation Information. Basic Configuration. Structure
<Abbreviations> Operation panel (FR-DU04) Operation panel (FR-DU04) parameter unit (FR-PU04) Inverter Mitsubishi transistorized inverter FR-A500 series Parameter number operation Operation using (FR-DU04/FR-PU04) External operation Operation using control circuit signals Combined operation Operation using both (FR-DU04/FR-PU04) external operation FR-A200E Mitsubishi transistorized inverter FR-A200 series <EXCELLENT> series
CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER APPENDICES
OUTLINE INSTALLATION WIRING OPERATION PARAMETERS PROTECTIVE FUNCTIONS SPECIFICATIONS OPTIONS
Pre-Operation Information
OUTLINE
OUTLINE Pre-Operation Information
1.1.1 Precautions operation
Incorrect handling might cause inverter operate improperly, life reduced considerably, worst, inverter damaged. Handle inverter properly accordance with information each section well precautions instructions this manual correctly. This manual written FR-A500 series transistorized inverters. handling information parameter unit (FR-PU04), inboard options, stand-alone options, etc., refer corresponding manuals.
Unpacking product check
Unpack inverter check capacity plate front cover rating plate inverter side face ensure that product agrees with your order inverter intact. Inverter type
Capacity plate Rating plate MITSUBISHI
MODEL
INVERTER
FR-A520-0.4K/
Input rating Inverter type Serial number Output rating Serial number Rating plate Capacity plate
FR-A520-0.4K
0.4kW XXXXX XXXXX
Inverter type Applicable motor capacity
POWER INPUT
OUTPUT
SERIAL MITSUBISHI ELECTRIC CORPORATION
MADE JAPAN
A520 0.4K
Symbol A520 A540
Voltage Class 200V class 400V class
Symbol Applicable Motor Capacity 0.4K Indicates capacity "kW".
Symbol Specifications None Japanese specifications U.S. specifications European specifications
Accessory Instruction manual have found discrepancy, damage, etc., please contact your sales representative.
Preparations instruments parts required operation
Instruments parts prepared depend inverter operated. Prepare equipment parts necessary. (Refer page 45.)
Installation
operate inverter with high performance long time, install inverter proper place, correct direction, with proper clearances. (Refer page
Wiring
Connect power supply, motor operation signals (control signals) terminal block. Note that incorrect connection damage inverter peripheral devices. (See page 12.)
Basic Configuration
OUTLINE
Basic Configuration
1.2.1 Basic configuration
following devices required operate inverter. Proper peripheral devices must selected correct connections made ensure proper operation. Incorrect system configuration connections cause inverter operate improperly, life reduced considerably, worst case, inverter damaged. Please handle inverter properly accordance with information each section well precautions instructions this manual. (For connections peripheral devices, refer corresponding manuals.)
Name Power supply Earth leakage circuit breaker (ELB) no-fuse breaker (NFB) Description power supply within permissible power supply specifications inverter. (Refer page 39.) breaker should selected with care since large inrush current flows inverter power (Refer page 39.) magnetic contactor need provided. When installed, start stop inverter. might reduce inverter life. (Refer page 39.) reactors must used when power factor improved inverter installed near large power supply system (1000KVA more wiring distance within (32.81 feet)). Make selection carefully. inverter life influenced ambient temperature. ambient temperature should possible within permissible range. This must noted especially when inverter installed enclosure. (Refer page
Incorrect wiring might lead inverter
(NFB) (ELB)
Magnetic contactor
(MC)
Reactors
reactor (FR-BAL)
reactor (FR-BEL)
Inverter
Ground
Devices connected output
damage. control signal lines should kept away from main circuit protect them from noise. (Refer page connect power capacitor, surge suppressor radio noise filter output side.
Ground
prevent electric shock, always ground motor inverter.
Ground
Japanese Harmonic Suppression Guideline
"harmonic suppression guideline household appliances general-purpose products" issued Ministry International Trade Industry September, 1994. This guideline applies FR-A520-0.4K 3.7K. connection power factor improving reactor (FR-BEL FR-BAL), this product conforms "harmonic suppression technique transistorized inverters (input current less)" forth Japan Electrical Manufactures' Association.
Structure
OUTLINE
Structure
1.3.1 Appearance structure
Front view
POWER lamp ALARM lamp
Without front cover
connector (Provided with modular jack type relay connector) (For RS-485 cable) Operation panel (FR-DU04) Brake resistor* (Fitted back) Inboard option mounting position Accessory cover Wiring port cover option Front cover Rating plate Capacity plate Control circuit terminal block Main circuit terminal block Wiring cover Modular jack type relay connector compartment
*7.5K less inverters equipped with inboard brake resistor. Note: "EC" version FR-A500 uses pheonix type connectors control circuit terminal block.
OUTLINE
1.3.2 Removal reinstallation front cover
FR-A520-0.4K 11K, FR-A540-0.4K 7.5K
Removal Hold both sides front cover push front cover down. Hold down front cover pull toward remove. (The front cover removed with (FR-DU04/FR-PU04) on.)
Catch
Front cover
Inverter
Reinstallation Insert catches bottom front cover into sockets inverter. Using catches supports, securely press front cover against inverter. Note: When operation panel mounted front cover removed, remove operation panel before reinstalling front cover.
FR-A520-15K 22K, FR-A540-11K
Removal Remove installation screw front cover. Hold both ends front cover top. Pull front cover toward remove. (The front cover removed with (FR-DU04/FR-PU04) on.)
Reinstallation Insert catches front cover bottom into sockets inverter. Using catches supports, securely press front cover against inverter. front cover with screw. Note: When operation panel mounted front cover removed, remove operation panel before reinstalling front cover.
OUTLINE
FR-A520-30K 55K, FR-A540-30K
Removal Remove front cover mounting screws.
Reinstallation front cover with mounting screws.
Note: Make sure that front cover been reinstalled securely. same serial number printed capacity plate front cover rating plate inverter. Before reinstalling front cover, check serial number ensure that cover removed reinstalled inverter from where removed.
OUTLINE
1.3.3 Removal reinstallation operation panel
ensure safety, remove reinstall operation panel after switching power off. Removal Hold down button operation panel pull operation panel toward remove.
Removal
Reinstallation
reinstall, insert straight mount securely. Reinstallation using connection cable Remove operation panel. Disconnect modular jack type relay connector. (Place disconnected modular jack type relay connector modular jack type relay connector compartment.)
Modular jack type relay connector Modular jack type relay connector compartment
Securely plug connection cable into connector (modular jack type relay connector) inverter other into operation panel.
Note: Install operation panel only when front cover inverter.
CHAPTER
INSTALLATION WIRING
This chapter gives information basic "installation wiring" this product. Always read instructions this chapter before using equipment.
Installation. Wiring Other wiring
CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER APPENDICES
OUTLINE INSTALLATION WIRING OPERATION PARAMETERS PROTECTIVE FUNCTIONS SPECIFICATIONS OPTIONS
Installation
INSTALLATION WIRING
INSTALLATION WIRING Installation
2.1.1 Instructions installation
Handle unit carefully. inverter uses plastic parts. Handle gently protect from damage. Also, hold unit with even strength apply much strength front cover alone. Install inverter place where immune vibration. (5.9 {0.6G} less) Also note cart, press, etc. Note ambient temperature inverter life under great influence ambient temperature. place installation, ambient temperature must within permissible range (depending upon operation mode conditions (see ambient temperature specifications page 190). Check that ambient temperature within that range positions shown figure Install inverter non-combustible surface. inverter will very (maximum about 150°C). Install non-combustible surface (e.g. metal). Also leave sufficient clearances around inverter. Avoid high temperature high humidity. Avoid places where inverter subjected direct sunlight, high temperature high humidity. amount heat generated enclosure reduced considerably placing heat sink outside enclosure. Note: option (FR-A5CN) installation. mounting area should panel cutting dimensions. cooling section outside enclosure cooling fan. inverter environment where exposed waterdrops, mist, dust, etc. Avoid places where inverter exposed mist, flammable gases, fluff, dust, dirt etc. Install inverter clean place inside "totally enclosed" panel which does accept suspended matter. Note cooling method when inverter installed enclosure. When more inverters installed ventilation mounted enclosure, inverters ventilation must installed proper positions with extreme care taken keep ambient temperatures inverters below permissible value. they installed improper positions, ambient temperatures inverters will rise ventilation effect will reduced. Install inverter securely with screws bolts vertical direction. Note ambient temperature Clearances around inverter
(1.97 inches) more 10cm (3.94 inches) more (1.97 inches) more Leave sufficient clearances above under inverter ensure adequate ventilation. Cooling built inverter Cooling
Measurement position (1.97 inches) (1.97 inches) (1.97 inches)
Measurement position
10cm (3.94 inches) more
(0.39 inches) more model 3.7K less
INSTALLATION WIRING
installation enclosure
Ventilation Inveter Inveter Inveter Inveter Inveter Built-in cooling (Correct example) (Incorrect example) (Correct example) (Incorrect example) Inveter
Position Ventilation
Accommodation more inverters
Vertical mounting
Wiring cover handling (22K less)
When cable conduits connected protective bushes wiring cover with nippers cutter before running cables.
Wiring cover
Protective bush
WARNING
remove protective bushes. Otherwise, cable sheathes scratched wiring cover edges, resulting short circuit ground fault. When cable conduits connected Remove corresponding protective bushes connect cable conduits.
Wiring
INSTALLATION WIRING
Wiring
2.2.1 Terminal connection diagram
version
version
3-phase power supply
Jumper
(Note) (Note) connector (RS-485) Jumper 24VDC power output external transistor common (Contact input common source logic)
Motor Ground Jumper Remove this jumper when using FR-BEL.
3-phase power supply
Jumper Remove this jumper when using FR-ABR.
Forward rotation start Reverse rotation start Start self-holding selection High Multi-speed selection Middle mode Second acceleration/deceleration time selection Output stop Reset Current input selection Selection automatic restart after instantaneous power failure (Contact input common sink logic) Control input signals voltage input allowed) Frequency setting signals (analog)
STOP
Note: Terminals provided FR-A520-0.4K 7.5K. FR-A540-0.4K 7.5K
Running frequency Instantaneous power failure Overload Frequency detection Open collector output common Common sink source Open collector outputs Alarm detection
10E(+10V) 10(+5V)
Meter (e.g. frequency meter) Moving-coil type full-scale
Frequency setting potentiometer 1/2W1k
Common Auxiliary input Current input
5VDC Selected 10VDC
(Analog common)
Analog signal output 10VDC)
5VDC Selected ±10VDC
20mADC)
Ground
Main circuit terminal Control circuit input terminal Control circuit output terminal
INSTALLATION WIRING
Description main circuit terminals
Symbol L11, Terminal Name power input Inverter output Power supply control circuit Brake resistor connection Brake unit connection Power factor improving reactor connection Built-in brake circuit connection Ground Description Connect commercial power supply. Keep these terminals unconnected when using high power factor converter (FR-HC). Connect three-phase squirrel-cage motor. Connected power supply terminals retain alarm display alarm output when using high power factor converter (FR-HC), remove jumpers from terminals R-R1 S-S1 L1-L11 L2-L21 apply external power these terminals. Disconnect jumper from terminals PR-PX connect optional brake resistor (FR-ABR) across terminals P-PR. Connect optional FR-BU brake unit, power return converter (FR-RC) high power factor converter (FR-HC). Disconnect jumper from terminals P-P1 connect optional power factor improving reactor (FR-BEL). When jumper connected across terminals PX-PR (factory setting), built-in brake circuit valid. (Provided 7.5K less.) grounding inverter chassis. Must earthed.
Note: Terminal names parentheses those version.
Description control circuit terminals
Type Symbol Terminal Name Forward rotation start Description Turn signal start forward rotation turn stop. Acts programmed operation start signal programmed operation mode. (Turn start turn stop.) Turn signal start reverse rotation turn stop. When signals turned simultaneously, stop command given.
STOP Contacts, e.g. start (STF), stop (STOP) etc.
Reverse rotation start Start self-holding selection Multi-speed selection
Turn STOP signal select self-holding start signal.
Input signals
signals appropriate select multiple speeds. Turn signal select operation (factory setting). Input terminal mode selection operation performed with start signal (STF function selection STR). (Pr. 186) change Turn signal select second acceleration/ terminal Second acceleration/ deceleration time. When second functions such "second deceleration time torque boost" "second (base frequency)" functions have functions. selection been set, these functions also selected turning signal. Turn signal (20ms longer) stop inverter output. Output stop Used shut inverter output bring motor stop magnetic brake. Used reset protective circuit activated. Turn signal more than Reset second, then turn off. Current input Only when signal turned inverter Input terminal selection operated with 4-20mADC frequency setting signal. function selection (Pr. With signal restart made automatically when Automatic restart after 186) change power restored after instantaneous power failure. Note instantaneous power terminal that this operation requires restart parameters set. When failure selection inverter shipped from factory, disallow restart. functions. Contact input Common contact input terminals terminal Common output terminal common (sink) 24VDC 0.1A power terminal). 24VDC power When transistor output (open collector output), such programmable controller, external transistor connected, connect external power supply common transistor output this common terminal prevent fault caused leakage current. This terminal used Contact input 24VDC, 0.1A power output. When source logic been selected, this terminal common (source) serves contact input common.
INSTALLATION WIRING
Type Symbol Analog frequency setting Frequency setting power supply Terminal Name Description When frequency setting potentiometer connected factory-set state, connect terminal 5VDC, permissible load current When connected terminal 10E, change 10mA input specifications terminal entering 5VDC 10VDC), maximum output frequency reached 10V) proportional. Switch between input 5VDC (factory setting) 10VDC from operation panel. Input resistance 10k. Maximum permissible voltage 20V. entering 20mADC, maximum output frequency reached 20mA proportional. This input signal valid only when signal Input resistance 250. Maximum permissible current 30mA. entering ±5VDC ±10VDC, this signal added frequency setting signal terminal Switch between input ±5VDC ±10VDC (factory setting) from operation panel. Input resistance 10k. Maximum permissible voltage ±20V. Common frequency setting signal (terminal analog output terminal earth. Change-over contact output indicating that output been stopped inverter protective function activated. 200VAC 0.3A, 30VDC 0.3A. Alarm: discontinuity across (continuity across A-C), normal: continuity across (discontinuity across A-C). Switched when inverter output frequency equal higher than starting frequency (factory 0.5Hz, variable). Switched high during stop dynamic brake operation (*2). Permissible load 24VDC 0.1A. Output terminal Switched when output frequency reached within function selection ±10% frequency (factory setting, variable). Switched (Pr. high during acceleration, deceleration stop (*2). Permissible 195) change load 24VDC 0.1A. terminal Switched when stall prevention function caused stall functions. prevention activated. Switched high when stall prevention reset (*2). Permissible load 24VDC 0.1A. Switched when instantaneous power failure undervoltage protection activated (*2). Permissible load 24VDC 0.1A. Switched when output frequency reached exceeded detection frequency appropriate. Switched high when below detection frequency (*2). Permissible load 24VDC 0.1A 10VDC, permissible load current 10mA Common RUN, terminals. Factory setting output item: Frequency selected from Permissible load current monitoring items, such 1440 pulses/second 60Hz output frequency, output. (*3) output signal Factory setting output item: proportional magnitude Frequency each monitoring item. Output signal 10VDC Permissible load current With operation panel connector, communication made through RS-485. connector
Input signals
Frequency setting (voltage) Frequency setting (current) Auxiliary frequency setting Frequency setting input common
Contact
Alarm output
Inverter running
Open collector
frequency
Output signals
Overload alarm Instantaneous power failure Frequency detection Open collector output common meter
Pulse
Analog
Analog signal output
Communication
Conforming Standard Standard RS-485 Transmission format Multi-drop link Communication speed Maximum 19200 baud rates Overall length 500m
RS-485
Terminals provided FR-A520-0.4K 7.5K, FR-A540-0.4K 7.5K. indicates that open collector outputting transistor (conducts). High indicates that transistor (does conduct). output while inverter reset.
INSTALLATION WIRING
2.2.2 Wiring main circuit
Wiring instructions
Crimping terminals with insulation sleeves recommended with power motor cables. protective bushes wiring cover when running cables. (22K less) Power must applied output terminals inverter. Otherwise inverter will damaged. After wiring, wire off-cuts must left inverter. Wire off-cuts cause alarm, failure malfunction. Always keep inverter clean. When drilling mounting holes control etc., exercise care prevent chips other foreign matter from entering inverter. cables recommended size wiring make voltage drop less. wiring distance long between inverter motor, main circuit cable voltage drop will cause motor torque decrease especially output frequency. overall wiring length should 500m (1640.40feet) maximum. Especially long distance wiring, overcurrent protection misactivated devices connected output side misoperate become faulty under influence charging current stray capacitance wiring. Therefore, maximum overall wiring length should indicated following table. (When more motors connected inverter, total wiring length should within indicated value.)
Inverter Capacity Non-low acoustic noise mode acoustic noise mode 0.4K 300m (984.24 feet) 200m (656.16 feet) 0.75K 500m (1640.40 feet) 300m (984.24 feet) 1.5K more 500m (1640.40 feet) 500m (1640.40 feet)
Overall wiring length (1.5K more)
500m (1640.40 feet) maximum
300m (984.24 feet) 300m (984.24 feet)
300m (984.24 feet) 300m (984.24 feet) 600m (1968.48 feet)
Connect only recommended optional brake resistor between terminals These terminals must shorted. Electromagnetic wave interference input/output (main circuit) inverter includes harmonic components, which interfere with communication devices (such radios) used near inverter. this case, install FR-BIF optional radio noise filter (for input side only) FR-BSF01 FR-BLF line noise filter minimize interference. install power capacitor, surge suppressor radio noise filter (FR-BIF option) output side inverter. This will cause inverter trip capacitor surge suppressor damaged. above devices installed, immediately remove them. FR-BIF radio noise filter connected, switching power during motor operation result E.UVT. this case, connect radio noise filter primary side electromagnetic contactor.)
INSTALLATION WIRING
When rewiring after operation, make sure that POWER lamp gone off, when more than minutes have elapsed after power-off, check with tester that voltage zero. After that, start rewiring work. some time after power-off, there dangerous voltage capacitor. space left-hand side main circuit terminal block cable connection control circuit power terminals L11, FR-A520-11K.
Connection cable
Charge lamp Screw size (M5)
CAUTION
residual current protective device only protection against indirect contact. Protective earth connection essential. connect more than wires protective earth terminal. contactor fuse breaker EN/IEC standard compliant. transformer surge absorber EN/IEC standard compliant.
Notes Grounding
Leakage currents flow inverter. prevent electric shock, inverter motor must grounded (200V class.class grounding, grounding resistance maximum), (400V class. special class grounding, grounding resistance less.). dedicated ground terminal ground inverter. screw case, chassis, etc.) (Unit: ground cable should thick possible. Ground Cable Gauge Motor Capacity gauge should equal larger than those 200V class 400V class indicated following table. grounding 3.7kW (5HP) less point should near possible inverter 5.5k, 7.5Kw (7.5HP, 10HP) 15Kw 20HP) minimize ground cable length. 18.5 37kW 50HP) Ground motor inverter side using 55Kw (60, 75HP) wire 4-core cable.
INSTALLATION WIRING
Terminal block layout
main circuit inverter, terminals arranged shown below: 200V class FR-A520-0.4K, 0.75K
Charge lamp Jumper (M4)
FR-A520-15K, 18.5K,
Screw size(M4)
Charge lamp Screw size (M4)
Screw size 15K(M6) 18.5K,22K(M8)
Jumper
Screw size (M6)
FR-A520-1.5K, 2.2K, 3.7K
Screw size (M4) Jumper (M4) Charge lamp
FR-A520-30K
Charge lamp Screw size (M4)
Screw size (M8)
Screw size (M6)
Jumper
FR-A520-5.5K, 7.5K
Screw size (M4) Charge lamp Screw size(M5)
FR-A520-37K,
Charge lamp Screw size (M4)
Screw size (M10)
Screw size (M8)
Jumper
(M5)
Jumpers
FR-A520-11K
Charge lamp Screw size (M5) Screw size (M4)
FR-A520-55K
Charge lamp Screw size (M4)
Screw size (M12)
Screw size (M8) Jumper
Jumper
Screw size (M5)
INSTALLATION WIRING
400V class FR-A540-0.4K, 0.75K, 2.2K, 3.7K
Screw size (M4) Jumper (M4) Screw size (M6) Jumper Charge lamp Charge lamp
FR-A540-30K
Screw size (M4)
Screw size (M6)
FR-A540-5.5K, 7.5K
Charge lamp Screw size (M4) Screw size (M4)
FR-A540-37K, 45K,
Charge lamp Screw size (M4)
Screw size (M8)
Screw size (M8)
Jumper
(M5)
Jumpers
FR-A540-11K, 15K, 18.5K,
Charge lamp Screw size (M4)
Screw size (M6)
Jumper Screw size (M6)
Note: Terminal names parentheses those version.
INSTALLATION WIRING
Cables, crimping terminals, etc.
following table lists cables crimping terminals used with inputs outputs inverter torques tightening screws:
Applicable Inverter Type Terminal Screw Size Tightening Torque (14) (14) (24) Crimping Terminals 2.5-4 5.5-4 5.5-5 14-5 16-5 14-5 16-5 22-6 35-6 38-8 35-8 38-8 70-8 60-8 95-8 100-10 95-8 100-10 150-12 2.5-4 5.5-4 5.5-4 5.5-6 14-6 16-6 14-6 16-6 22-6 25-6 22-6 25-6 38-8 37-8 38-8 50-8 60-8 70-8 2.5-4 5.5-4 2.5-4 5.5-5 14-5 16-5 22-6 16-6 38-8 25-8 38-8 35-8 60-8 30-8 100-10 70-8 100-10 95-40 150-12 110-12 2.5-4 2.5-4 5.5-4 5.5-6 10-6 10-6 14-6 16-6 22-6 25-6 22-8 25-8 38-8 35-8 60-8 50-8 Cables (Note MCM300 MCM300
FR-A520-0.4K 2.2K FR-A520-3.7K FR-A520-5.5K FR-A520-7.5K FR-A520-11K FR-A520-15K FR-A520-18.5K FR-A520-22K FR-A520-30K FR-A520-37K FR-A520-45K FR-A520-55K FR-A540-0.4K 3.7K FR-540-5.5K FR-540-7.5K FR-540-11K FR-540-15K FR-540-18.5K FR-540-22K FR-540-30K FR-540-37K FR-540-45K FR-540-55K
Note: cables used should 75°C (167°F) copper cables. Tighten terminal screws specified torques. Undertightening cause short misoperation. Overtightening cause screws unit damaged, resulting short misoperation.
Connection power supply motor
Power supply Ground terminal No-fuse breaker
Motor Ground
Ground
power supply cables must connected they connected inverter will damaged. Phase sequence need matched. with single-phase power supply,the power supply cables must connected
Connect motor above connection, turning forward rotation switch (signal) rotates motor counterclockwise (arrow) direction when viewed from load shaft.
INSTALLATION WIRING
Connecting control circuit power supply separately from main circuit
magnetic contactor (MC) inverter power supply opened when protective circuit operated, inverter control circuit power lost alarm output signal cannot kept keep alarm signal terminals available. this case, connect power supply terminals control circuit primary side
Model FR-A520-0.4K 3.7K, FR-A540-0.4K 3.7K
<Connection procedure>
Terminal block main circuit
Loosen upper screws Remove lower screws. Remove jumpers. Connect separate power supply cables control circuit lower terminals (R1, L11, L21). (Note
Model FR-A520-5.5K 55K, FR-A540-5.5K
<Connection procedure>
Power supply terminal block control circuit Power supply terminal block control circuit
Loosen upper screws. Remove lower screws. Pull remove jumper. Connect separate power supply cables control circuit upper terminals (R1, L11, L21). (Note
Main power supply
Note: When main circuit power switch control power (terminals L11, L21). Otherwise inverter damaged. When using separate power supply, jumpers across R-R1 S-S1 L1-L11 L2-L21 must removed. Otherwise inverter damaged. different power supply system which takes power control circuit from other than primary side voltage should equal main circuit voltage. FR-A520-5.5K 55K, FR-A540-5.5K 55K, power supply cables must connected lower terminals. connected, inverter damaged.
INSTALLATION WIRING
2.2.3 Wiring control circuit
Wiring instructions
Terminals common signals isolated from each other. These common terminals must connected each other earthed. shielded twisted cables connection control circuit terminals them away from main power circuits (including 200V relay sequence circuit). frequency input signals control circuit micro currents. When contacts required, more parallel micro signal contacts twin contact prevent contact fault. recommended cables 0.75mm gauge connection control circuit terminals. cable gauge used 1.25mm more, front cover lifted when there many cables running cables improperly, resulting operation panel parameter unit contact fault.
Terminal block layout
version
control circuit inverter, terminals arranged shown below: Terminal screw size: M3.5
STOP
version
Terminal screw size: M3.5
STOP
<Wiring procedure>
wiring control circuit, strip sheaths cables them they are. Strip sheath following dimension. long stripping dimension cause short circuit with neighboring cable. short dimension cause cable disconnection.
Loosen terminal screw insert cable into terminal. Tighten screw specified torque. Undertightening cause cable disconnection malfunction. Overtightening cause short circuit malfunction screw unit damaged. Tightening torque: kgfcm Note: Wire stripped cable twisting prevent from becoming loose. plate cable with solder.) Note: fuse breakers) fuse inverter input (primary) side. Make sure that control circuit terminal wiring does touch power circuit terminals screws) conducting power circuit.
INSTALLATION WIRING
Changing control logic
input signals sink logic Japanese version, source Logic version. change control logic, connector back control circuit terminal block must moved other position. (The output signals used either sink source logic independently connector position.) Loosen mounting screws both ends control circuit terminal block. (The screws cannot removed.) With both hands, pull down terminal block from back control circuit terminals.
Remove connector from rear surface control circuit terminal block place required Logic position (either Sink Source).
version
Japanese version
Using care bend pins control circuit connector, reinstall control circuit terminal block with mounting screws. Note: Make sure that control circuit connector fitted correctly. While power never disconnect control circuit terminal block. sink-source logic change-over connector must fitted only those positions. fitted both positions same time, inverter damaged.
SINK
CON1
INSTALLATION WIRING
Sink logic type this logic, signal switches when current flows corresponding signal input terminal. Terminal common contact input signals. Terminal common open collector output signals.
Current current flows corresponding signal
When using external power supply transistor output, terminal common prevent misoperation caused leakage current. connect terminal inverter with terminal external power supply.)
AY40 type transistor output module
Inverter DC24V (SD)
DC24V
INSTALLATION WIRING
Source logic type this logic, signal switches when current flows into corresponding signal input terminal. Terminal common contact input signals. Terminal common open collector output signals.
current flows corresponding signal
Current
When using external power supply transistor output, terminal common prevent misoperation caused leakage current.
Inverter AY-80 DC24V (SD)
DC24V
terminals "STOP", "CS" "PC"
Using "STOP" terminal connection example (for sink logic) self-holding start signal (forward rotation, reverse rotation) shown right. Using "CS" terminal This terminal used perform automatic restart after instantaneous power failure commercial power supply-inverter switch-over operation. <Example: Automatic restart after instantaneous power failure sink logic> Connect terminals CS-SD value other than "9999" "coasting time automatic restart after instantaneous power failure".
Forward rotation Reverse rotation
STOP Stop
(Short)
Using "PC" terminal This terminal used 24VDC power output using common terminal. Specifications: 26VDC, 0.1A permissible current Note that wiring length should within 30m. short terminals PC-SD. When terminal used power supply, leakage current from transistor output cannot prevented.
INSTALLATION WIRING
2.2.4 Connection connector
When connecting operation panel parameter unit using connection cable
<Recommended cable connector> Parameter unit connection cable (FR-CB2) (option) following connector cable. Connector: RJ45 connector Example: 5-554720-3, Nippon Cable: Cable conforming EIA568 (e.g. 10BASE-T cable) Example: SGLPEV MITSUBISHI CABLE INDUSTRIES, LTD. Note: maximum wiring length (65.62 feet).
RS-485 communication
With operation panel disconnected, connector used communication operation from personal computer etc. When connector connected with personal, other computer communication cable, user program allows inverter monitored parameter values read written. connector pin-outs> Viewed from inverter (receptacle side) front
Note: connect connector computer's board, modem socket telephone modular connector. Otherwise, product damaged electrical specification differences. Pins (P5S) provide power operation unit parameter unit. these pins RS-485 communication.
<System configuration example> When computer having RS-485 interface used with several inverters
Computer Station Inverter 10BASE-T cable
connector
Station Inverter
connector
Station Inverter
connector
RS-485 interface/terminal Computer
Terminal resistor jumper Distribution terminal
Note: connector cables which available market. Connector: RJ45 connector Example: 5-554720-3, Nippon Co., Ltd. Cable: Cable conforming EIA568B (such 10BASE-T cable) Example: SGLPEV Mitsubishi Cable Industries, Ltd.
INSTALLATION WIRING
When computer having RS-232C interface used with inverters
Computer
Station RS-232C connector RS-232C cable Max. *Converter Inverter
connector
Station Inverter
connector
Station Inverter
connector
RS-485 terminal Distribution terminal 10BASE-T cable *Converter available market required.
Terminal resistor jumper
Note: connector, cables converter which available market. Connector: RJ45 connector Example: Nippon Co., Ltd. Cable: Cable conforming EIA568B (such 10BASE-T cable) Example: SGLPEV Mitsubishi Cable Industries, Ltd. RS-485/RS-232C converter Example: FA-T-RS40, Industrial System Div., Mitsubishi Electric Engineering Co., Ltd. Cable with built-in interface DAFXI-CAB series, Connector conversion cable DINV-485CAB, Trend Co., Ltd. <Wiring method> Wiring computer inverter
Computer Side Terminals Signal name Description Receive data Receive data Send data Send data Request send Request send Clear send Clear send Signal ground Frame ground 0.3mm2 more Cable connection signal direction 10BASE-T Cable Inverter
connector
Terminal resistor jumper
Wiring computer inverters (several inverters)
Computer Station Inverter Station Inverter Terminal resistor jumper (*1)
Station Inverter
Note: Connect terminal resistor jumper only inverter remotest from computer. (Terminal resistor: Make connections accordance with instruction manual computer used. Fully check terminal numbers computer they differ between models.
INSTALLATION WIRING
2.2.5 Connection stand-alone option units
inverter accepts variety stand-alone option units required. Incorrect connection will cause inverter damage accident. Connect operate option unit carefully accordance with corresponding option unit manual.
Connection dedicated external brake resistor (option)
built-in brake resistor connected across terminals external dedicated brake resistor (option) instead when built-in brake resistor does have enough thermal capability high-duty operation. Remove jumper from across terminals PR-PX connect dedicated brake resistor (option) across terminals P-PR -PR. (For positions terminals refer terminal block arrangement (page14 15).)
Note: brake resistor connected should only dedicated brake resistor. jumper across terminals PR-PX must disconnected before connecting dedicated brake resistor. failure damage inverter.
Model.FR-A520-0.4K 3.7K, FR-A540-0.4K 3.7K
Remove screws terminals remove jumper. Connect brake resistor across terminals P-PR -PR. (The jumper should remain disconnected.)
Removal jumper FR-A520-0.4K, 0.75K FR-A520-1.5K 3.7K FR-A540-0.4K 3.7K
Terminal Terminal Terminal Terminal Terminal
Jumper Terminal
Model.FR-A520-5.5K, 7.5K, FR-A540-5.5K, 7.5K
Remove screws terminals remove jumper. Connect brake resistor across terminals P-PR -PR. (The jumper should remain disconnected.)
Removal jumper FR-A520-5.5K, 7.5K FR-A540-5.5K, 7.5K
Terminal
Terminal
Terminal
Jumper
Terminal
INSTALLATION WIRING
Connection FR-BU brake unit (option)
Connect optional FR-BU brake unit shown below improve braking capability during deceleration.
(Note
Motor
Inverter Remove jumper.
N/HA
Resistor unit FR-BR-(H)
Brake unit FR-BU-(H)
Note: Connect inverter terminals FR-BU brake unit terminals that their terminal signals match with each other. (Incorrect connection will damage inverter.) model 7.5K less, jumper across terminals PR-PX must removed. wiring distance between inverter, brake unit resistor unit should within (16.40 feet). twisted wires used, distance should within (32.8 feet). transistors brake unit should fail, resistor will extremely hot, causing fire. Therefore, install magnetic contactor inverter's power supply side shut current case failure. power supply 400V class, install voltage-reducing transformer.
INSTALLATION WIRING
Connection conventional brake unit (option)
Connect brake unit correctly shown right. Incorrect connection will damage inverter.
Inverter Motor
Remove jumpers. (Note Discharge resistor
Constant-voltage power supply
Comparator
brake unit
Brake unit
Note: models 7.5K less, remove jumper across terminals PR-PX. wiring distance between inverter, brake unit discharge resistor should within (6.56 feet). twisted wires used, distance should within (16.40 feet). transistors brake unit should fail, resistor will extremely hot, causing fire. Therefore, install magnetic contactor inverter's power supply side shut current case failure. power supply 400V class, install voltage-reducing transformer.
Connection FR-HC high power factor converter (option)
When connecting high power factor converter (FR-HC) suppress power harmonics, wire shown below. Wrong connection will damage high power factor converter inverter. After making sure that wiring correct, "regenerative function selection".
High power factor converter Inverter (FR-A500) (Note From FR-HCL02 (Note (Note Power supply (Note
INSTALLATION WIRING
Note: Remove jumpers across R-R1 S-S1 L1-R1 L2-S1 terminals inverter, connect control circuit power supply across R1-S1 L11-L21 terminals. power input terminals must open. Incorrect connection will damage inverter. Reverse polarity terminals (-), will damage inverter. voltage phases terminals terminals must matched before connection. (input terminal function selection) assign terminals used with signals. When FR-HC connected, sink logic (factory setting). source logic, FR-HC cannot connected. (For version, select sink logic.)
Connection FR-RC power return converter (option)
(For power coordination, always install power factor improving reactor (FR-BAL).) When connecting FR-RC power return converter, connect inverter terminals FR-RC power return converter terminals shown below that their signals match with each other. After making sure that wiring correct, "regenerative function selection".
Inverter
FR-RC power return converter
Power supply
FR-BAL
R/L1
S/L2
T/L3
Note: models less, jumper across terminals PR-PX must removed. connect FR-BAL power factor improving reactor (option) When using more inverters same system, small impedance between inverters will cause regenerative current from power return converter leak into other inverters, resulting overcurrent alarm other inverters. prevent this, install power factor improving reactor power supply side inverters.
Connection power factor improving reactor (option)
Connect FR-BEL power factor improving method> reactor between terminals P1-P this case, jumper connected across terminals P1-P must removed. Otherwise, reactor Remove jumper. will function.
FR-BEL
Note: wiring distance should within size cables used should equal larger than that power supply cables
INSTALLATION WIRING
2.2.6 Design information
commercial power supply-inverter switch-over operation, provide electrical mechanical interlocks designed commercial power supply-inverter switch-over. When there commercial power supply-inverter switch-over circuit shown below, inverter will damaged leakage current from power supply arcs generated time switch-over chattering caused sequence error. machine must restarted when power restored after power failure, provide magnetic contactor inverter's primary circuit also make sequence which will switch start signal. start signal (start switch) remains after power failure, inverter will automatically restart soon power restored. When power supply used with control circuit different from used with main circuit, make circuit which will switch main circuit power supply terminals when power supply terminals L11, control circuit switched off. Since input signals control circuit level, parallel micro signal contacts twin contact contact inputs prevent contact fault. apply large voltage contact input terminals (e.g. STF) control circuit. apply voltage directly alarm output signal terminals Always apply voltage these terminals relay coil, lamp, etc. Make sure that specifications rating match system requirements. Commercial power supply-inverter switch-over
Interlock Power supply (L2) (L3) Leakage current
Low-level signal contacts Twin contact
Low-level signal contacts
Inverter
Other wiring
INSTALLATION WIRING
Other wiring
2.3.1 Power harmonics
Power harmonics generated from converter section inverter, affecting power supply equipment, power capacitors, etc. Power harmonics different generation source, frequency transmission path from radio frequency (RF) noise leakage currents. Take following measures. differences between harmonics noise indicated below:
Item Frequency Environment Quantitative understanding Generated amount Immunity affected device Example safeguard Harmonics Normally 50th degrees, 3kHz less wire paths, power impedance Logical computation possible Approximately proportional load capacity Specified standards each device. Install reactor Noise High frequency (several 10kHz order) Accross spaces, distance, laying paths Occurs randomly, quantitative understanding difficult. According current fluctuation rate (larger with faster switching) Differs according maker's device specifications. Increase distance.
Safeguard harmonic current generated from inverter power supply differs according various conditions such wiring impedance, whether power factor improving reactor used not, output frequency output current load side. output frequency output current, adequate method obtain them under rated load maximum operating frequency.
Power factor improving reactor Motor Inverter
Power factor improving reactor
insert power factor improving capacitor
Note: power factor improving capacitor surge suppressor inverter's output overheat damaged harmonics inverter output. Also, when overcurrent flows inverter, overcurrent protection activated, Hence, when motor driven inverter, install capacitor surge suppressor inverter's output. improve power factor, insert power factor improving reactor inverter's input circuit.
INSTALLATION WIRING
2.3.2 Japanese harmonic suppression guidelines
Harmonic currents flow from inverter power receiving point power transformer. harmonic suppression guidelines were established protect other consumers from these outgoing harmonic currents. "Harmonic suppression guideline household appliances general-purpose products" This guideline issued Ministry International Trade Industries September, 1994 applies 200V class inverters 3.7kW (5HP) less. installing FR-BEL FR-BAL power factor improving reactor, inverters comply with "harmonic suppression techniques transistorized inverters (input current less)" established Japan Electrical Manufacturers' Association. Therefore install optional reactor 200V class, 3.7kW (5HP) less inverter. "Harmonic suppression guideline specific consumers" This guideline sets forth maximum values harmonic currents outgoing from high-voltage especially high-voltage consumer will install, renew harmonic generating equipment. maximum values exceeded, this guideline requires that consumer take certain suppression measures. Table Maximum Values Outgoing Harmonic Currents Contract Power
Received Power Voltage 6.6kV 22kV 33kV 0.86 11th 0.82 0.55 13th 0.69 0.46 17th 0.53 0.35 19th 0.47 0.32 23rd 0.76 0.39 0.26 Over 23rd 0.70 0.36 0.24
Application harmonic suppression guideline specific consumers
installation/addition/renewal equipment
Calculation equivalent capacity more than reference capacity
equivalent capacities
Over reference capacity Calculation outgoing harmomic current
outgoing harmonic current equal lower than maximum value more than maximum value
Over maximum value
Harmomic suppression technique required.
Harmomic suppression technique required.
Table Conversion Factors FR-A500 Series
Class Circuit Type Without reactor With reactor side) 3-phase bridge (Capacitor-smoothed) With reactor side) With reactors (AC, sides) Self-exciting 3-phase bridge When high power factor converter used Conversion Factor
INSTALLATION WIRING
Table Equivalent Capacity Limits
Received Power Voltage 6.6kV 22/33kV 66kV more Reference Capacity 50kVA 300kVA 2000kVA
Table Harmonic Content (Values fundamental current 100%)
Reactor used Used side) Used side) Used (AC, sides) 14.5 11th 13th 17th 19th 23rd 25th
Calculation equivalent capacity (P0) harmonic generating equipment "equivalent capacity" capacity 6-pulse converter converted from capacity consumer's harmonic generating equipment calculated with following equation. equivalent capacities higher than limit Table harmonics must calculated with following procedure:
Rated capacity: Determined capacity [kVA] applied motor found Table Conversion factor (refer Table should noted that rated capacity Rated capacity harmonic generating equipment* [kVA] used here used calculate generated Number indicating conversion circuit type harmonic amount different from
power supply capacity required actual inverter drive.
Calculation outgoing harmonic current Outgoing harmonic current fundamental wave current (value converted from received power voltage) operation ratio harmonic content Operation ratio: Operation ratio actual load factor operation time ratio during minutes Harmonic content: Found Table Table Rated Capacities Outgoing Harmonic Currents Inverter Drive
Applied Rated Current Motor (HP)) 200V 400V (0.5) 0.81 0.75 1.37 2.75 applied 3.96 6.50 (7.5) 19.1 9.55 (10) 25.6 12.8 (15) 36.9 18.5 (20) 49.8 24.9 18.5 (25) 61.4 30.7 (30) 73.1 36.6 (40) 98.0 49.0 (50) 60.4 (60) 73.5 (75) 89.9 Fundamental Wave Current Converted from 6.6kV (mA) 1121 1509 1860 2220 2970 3660 4450 5450 Rated Capacity (kVA) 0.57 0.97 1.95 2.81 4.61 6.77 9.07 13.1 17.6 21.8 25.9 34.7 42.8 52.1 63.7 31.85 53.95 108.6 156.0 257.1 376.1 504.4 728.7 980.9 1209 1443 1931 2379 2893 3543 Fundamental Wave Current Converted from 6.6kV reactor, 100% operation ratio) 20.09 34.03 68.47 98.40 161.5 237.4 318.2 459.6 618.7 762.6 910.2 1218 1501 1825 2235 11th 4.165 7.055 14.20 20.40 33.49 49.22 65.96 95.29 128.3 158.1 188.7 252.5 311.1 378.3 463.3 13th 3.773 6.391 12.86 18.48 30.34 44.58 59.75 86.32 116.2 143.2 170.9 228.7 281.8 342.7 419.7 17th 2.107 3.569 7.181 10.32 16.94 24.90 33.37 48.20 64.89 79.98 95.46 127.7 157.4 191.4 234.4 19th 1.519 2.573 5.177 7.440 12.21 17.95 24.06 34.75 46.78 57.66 68.82 92.07 113.5 138.0 169.0 23rd 1.274 2.158 4.342 6.240 10.24 15.05 20.18 29.15 39.24 48.36 57.72 77.22 95.16 115.7 141.7 25th 0.882 1.494 3.006 4.320 7.092 10.42 13.97 20.18 27.16 33.48 39.96 53.46 65.88 80.10 98.10
Harmonic suppression technique requirement outgoing harmonic current higher than; maximum value (contract power) contract power, harmonic suppression technique required.
INSTALLATION WIRING
Harmonic suppression techniques
Item Reactor installation (ACL, DCL) High power factor converter (FR-HC) Installation power factor improving capacitor Transformer multiphase operation filter Description Install reactor (ACL) side inverter reactor (DCL) side both suppress outgoing harmonic currents. converter circuit switched on-off convert input current waveform into sine wave, suppressing harmonic currents substantially. high power factor converter (FR-HC) used with standard accessory. When used with series reactor, power factor improving capacitor effect absorbing harmonic currents. transformers with phase angle difference combination provide effect corresponding pulses, reducing low-degree harmonic currents. capacitor reactor used together reduce impedance specific frequencies, producing great effect absorbing harmonic currents. This filter detects current circuit generating harmonic current generates harmonic current equivalent difference between that current fundamental wave current suppress harmonic current detection point, providing great effect absorbing harmonic currents.
Active filter
INSTALLATION WIRING
2.3.3 Inverter-generated noises reduction techniques
Some noises enter inverter causing misoperate others radiated inverter causing misoperation peripheral devices. Though inverter designed insusceptible noise, handles low-level signals, requires following basic measures taken. Also, since inverter chops output high carrier frequency, could generate noise. these noises cause peripheral devices misoperate, measures should taken suppress noise. measures differ slightly depending noise propagation paths. Basic measures power cables (I/O cables) signal cables inverter parallel with each other bundle them. twisted shielded cables detector connection control signal cables connect sheathes shielded cables terminal Ground inverter, motor, etc. point. Measures against noises which enter cause misoperation inverter When devices which generate many noises (which magnetic contactors, magnetic brakes, many relays, example) installed near inverter inverter effected noise, following measures must taken: Provide surge suppressors devices that generate noise suppress noise. data line filters signal cables. Ground shields detector connection control signal cables with cable clamp metal. Measures against noise which radiated inverter causing misoperation peripheral devices. Inverter-generated noise largely classified into those radiated cables connected inverter inverter main circuit (I/O), those electromagnetically electrostatically inducted signal cables peripheral devices close main circuit power supply, those transmitted through power supply cables.
Inverter-generated noise
Air-propagated noise
Noise directly radiated inverter Noise radiated power cables Noise radiated motor cables
Path Path Path
Magnetic induction noise Static induction noise Cable-propagated noise
Path 4),5) Path Noise propagated through power cables Noise from ground cable leakage current
Path
Path
INSTALLATION WIRING
Telephone
Instrument Receiver
In3) verter Motor
Sensor power supply
Sensor
Noise Path
Measures When devices which handle low-level signals susceptible misoperation noise (such instruments, receivers sensors) installed near inverter their signal cables contained same panel inverter near inverter, devices effected air-propagated noises following measures must taken: Install easily affected devices away possible from inverter. easily affected signal cables away possible from inverter. signal cables power cables (inverter cables) parallel with each other bundle them. Inset line noise filters into radio noise filters into input side suppress cable-radiated noises. shielded cables signal cables power cables them individual metal conduits reduce further effects. When signal cables parallel with bundled with power cables, magnetic static induction noise propagated signal cables effect devices following measures must taken: Install easily affected devices away possible from inverter. easily affected signal cables away possible form inverter. signal cables power cables (inverter cables) parallel with each other bundle them. shield cables signal cables power cables them individual metal conduits reduce further effects. When power supplies peripheral devices connected power supply inverter within same line, inverter-generated noise flow back through power supply cables misoperate devices following measures must taken: Install radio noise filter (FR-BIF) power cables (input cables) inverter. Install line noise filter (FR-BLF, FR-BSF01) power cables (I/O cables) inverter. When closed loop circuit formed connecting peripheral device wiring inverter, leakage current flow through ground cable inverter effect device. such case, disconnection ground cable device cause device operate properly.
INSTALLATION WIRING
Data line filter Noise entry prevented providing data line filter detector cable etc. Example Data line filter: ZCAT3035-1330 (TDK make) ESD-SR-25 (Tokin make) Impedance specifications (ZCAT3035-1330)
Impedance 100MHz 500MHz
39±1 34±1 Cable fixing band mounting section [Unit
above impedance values reference values guaranteed values.
13±1
Inverter d(cm) Motor Line-to-line distance, (cm)
Product name
number Outline Dimension Drawing (ZCAT3035-1330)
Data examples
decreasing carrier frequency, noise terminal voltage* reduced. carrier frequency value (1kHz). Though motor noise increases carrier frequency, selection Soft-PWM will make unoffending. Differences between Noise Terminal Voltages Different Carrier Frequencies
Conditions Motor: 3.7kW (5HP) Average terminal voltage 0dB=1µV 120dB=1V fc=2.0kHz Soft-PWM(Factory setting) fc=0.7kHz fc=14.5kHz FR-A520-3.7K FR-A220E-3.7k fc=(14.5kHz)
Noise terminal voltage (dB)
Noise frequency (MHz)
decreasing carrier frequency, noise will about that conventional FR-Z200 series.
Noise Terminal Voltage Inverter Example Reduction Noise ilters
Conditions Motor:3.7kW (5HP) Average terminal voltage 0dB=1µV 120dB=1V
using shielded cables signal cables, induction noise reduced greatly 1/10 1/100). Induction noise also reduced moving signal cables away from inverter output cables. (Separation 30cm (11.81 inches) reduces noise 1/2-1/3.) fitting FR-BSF01 inverter output side, induction noise signal cables reduced. Noise Induced Signal Cables Inverter Output Cables
Induction voltage (dB) Parallel cable Twisted pair cable
Noise terminal voltage (dB)
FR-Z220-3.7K
Conditions Inverter: FR-A520-3.7K Motor: FR-JR 3.7kW (5HP) Output frequency: 30Hz Noise form: Normal mode
Coaxial cable
FR-A520-3.7k(fc=0.7kHz)
FR-BLF Terminal FR-BSF01 (4T) Measuring instrument
Noise frequency (MHz)
*Noise terminal voltage: Represents magnitude noise propagated from inverter power supply.
30±1
INSTALLATION WIRING
Example measures against noises
Control Install filter (FR-BLF,FRBSF01) inverter input side. Inverter power supply Install filter FR-BIF inverter input side. FRBLF Reduce carrier frequency. Install filter (FR-BLF,FR-BSF01) inverter output side.
Inverter
FRBLF
Motor
FRBIF
4-core cable motor power cable cable ground cable.
Separate inverter power line 30cm (11.81 inches) more least 10cm (3.94 inches)) from sensor circuit. Control power supply Power supply sensor ground control directly. ground control cable.
twisted pair shielded cable. Sensor
ground shield connect signal common cable.
INSTALLATION WIRING
2.3.4 Leakage currents countermeasures
static capacitance existing inverter wiring motor, leakage currents flow through them. Since their values depend static capacitance, carrier frequency, etc., take following measures.
To-ground leakage currents
Leakage currents flow only into inverter's line also into other line through ground cable, etc. These leakage currents operate earth leakage circuit breakers earth leakage relays unnecessarily. Countermeasures Decrease carrier frequency (Pr. inverter. Note that motor noise increases. Selection Soft-PWM (Pr. 240) will make unoffending. using earth leakage circuit breakers designed harmonics surges (e.g. Mitsubishi's Progressive Super Series) inverter's line other line, operation performed with noise (with carrier frequency kept high)
To-ground leakage current Note that long wiring length will increase leakage currents. Decrease carrier frequency inverter reduce leakage currents. Higher motor capacity leads larger leakage currents. Larger leakage currents occur 400V class than 200V class.
Line-to-line leakage currents
Harmonics leakage currents flowing static capacities between inverter output cables operate external thermal relay unnecessarily. When wiring length long (50m (164.04 feet) more) 400V class small-capacity model (7.5kW (10HP) less), external thermal relay likely operate unnecessarily because ratio leakage current rated motor current increases. Line-to-Line Leakage Current Data Example (200V class)
Motor Capacity (HP)) (0.5) 0.75 (7.5) (10) Rated Motor Current 12.8 19.4 25.6 Leakage Current (mA) Wiring length Wiring length 100m (164.04 feet) (328.08 feet)
Motor: SF-J Carrier frequency: 14.5Hz Cable used: 4-core cable
Leakage current 400V class about twice larger.
Power supply Thermal relay Motor
Inverter Line static capacitances
Line-to-Line Leakage Current Path
Countermeasures electronic overcurrent protection (Pr. inverter. Decrease carrier frequency. Note that motor noise increases. Selection Soft-PWM (Pr. 240) will make unoffending. ensure that motor protected against line-to-line leakage currents, recommended temperature sensor directly detect motor temperature.
INSTALLATION WIRING
2.3.5 Inverter-driven 400V class motor
type inverter, surge voltage attributable wiring constants generated motor terminals. Especially 400V class motor, surge voltage deteriorate insulation. When 400V class motor driven inverter, consider following measures: Measures recommended take either following measures: Rectifying motor insulation 400V class motor, insulation-rectified motor. Specifically, Specify "400V class inverter-driven, insulation-rectified motor". dedicated motor such constant-torque motor low-vibration motor, "inverter-driven, dedicated motor". Suppressing surge voltage inverter side secondary side inverter, connect optional surge voltage suppression filter (FR-ASF-H).
INSTALLATION WIRING
2.3.6 Peripheral devices
Selection peripheral devices
Check capacity motor used with inverter purchased. Appropriate peripheral devices must selected according capacity. Refer following list prepare appropriate peripheral devices: 200V class
Inverter Type FR-A520-0.4K FR-A520-0.75K FR-A520-1.5K FR-A520-2.2K FR-A520-3.7K FR-A520-5.5K FR-A520-7.5K FR-A520-11K FR-A520-15K FR-A520-18.5K FR-A520-22K FR-A520-30K FR-A520-37K FR-A520-45K FR-A520-55K Motor Output (HP)) (0.5) 0.75 (7.5) (10) (15) (20) 18.5 (25) (30) (40) (50) (60) (75) Power Supply Capacity (kVA) No-Fuse Breaker Earth Leakage Circuit Breaker With power factor Standard improving reactor Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF50, NV50 Type NF50, NV50 Type NF100, NV100 Type NF50, NV50 Type NF100, NV100 Type NF100, NV100 Type NF225, NV225 125A Type NF100, NV100 100A Type NF225, NV225 150A Type NF225, NV225 125A Type NF225, NV225 175A Type NF225, NV225 150A Type NF225, NV225 225A Type NF225, NV225 175A Type NF400, NV400 250A Type NF225, NV225 225A Type NF400, NV400 300A Type NF400, NV400 300A Type NF400, NV400 400A Type NF400, NV400 350A Magnetic Contactor S-N10 S-N10 S-N10 S-N11,N12 S-N20 S-N25 S-N35 S-K50 S-K65 S-K80 S-K95 S-K125 S-K150 S-K180 S-K220
400V class
Inverter Type FR-A540-0.4K FR-A540-0.75K FR-A540-1.5K FR-A540-2.2K FR-A540-3.7K FR-A540-5.5K FR-A540-7.5K FR-A540-11K FR-A540-15K FR-A540-18.5K FR-A540-22K FR-A540-30K FR-A540-37K FR-A540-45K FR-A540-55K Motor Output (HP)) (0.5) 0.75 (7.5) (10) (15) (20) 18.5 (25) (30) (40) (50) (60) (75) Power Supply Capacity (kVA) No-Fuse Breaker Earth Leakage Circuit Breaker With power factor Standard improving reactor Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF30, NV30 Type NF50, NV50 Type NF50, NV50 Type NF100, NV100 Type NF50, NV50 Type NF100, NV100 Type NF100, NV100 Type NF100, NV100 100A Type NF100, NV100 Type NF225, NV225 125A Type NF100, NV100 100A Type NF225, NV225 150A Type NF225, NV225 125A Type NF225, NV225 175A Type NF225, NV225 150A Type NF225, NV225 200A Type NF225, NV225 175A Magnetic Contactor S-N10 S-N10 S-N10 S-N11,S-N12 S-N20 S-N20 S-N20 S-N20 S-N25 S-N35 S-K50 S-K65 S-K80 S-K80 S-K125
INSTALLATION WIRING
Selection rated sensitivity current earth leakage circuit breaker
When using earth leakage circuit breaker with follows, independent carrier frequency setting: Progressive Super Series (Type Rated sensitivity current: (lg1 lgm) Conventional series (Type Rated sensitivity current: {lg1 (lg2+lgm)} lg1, leakage currents cable path during commercial power supply operation lgn* leakage current noise filter inverter input side leakage current motor during commercial power supply operation inverter circuit, select rated sensitivity current
Example leakage current cable path during commercial power supply operation when cable routed metal conduit (200V 60Hz) Leakage current example 3-phase induction motor during commercial power supply operation (200V 60Hz)
Leakage current (mA)
Leakage current (mA)
1118.5 3045
Cable size
Motor capacity (kW)
<Example>
(16.40 feet) Noise filter Inverter (229.66 feet)
200V 2.2kW (3HP)
Progressive Super Note should installed Conventional Series (Type primary (power supply) side (Type (16.40 feet) inverter. 0.17 Leakage current 1000m (3280.80 feet) Ground fault secondary side Leakage current (without noise filter) inverter detected running (229.66 feet) 2.31 Leakage current 1000m (3280.80 feet) frequency 120Hz lower. Motor leakage current 0.18 connection neutral point ground Total leakage current 2.66 7.64 fault inverter secondary side. Reted sensitivity current protective ground resistance load equipment should less. When breaker grounded secondary side inverter, unnecessarily operated harmonics effective value less than rating. this case, note that eddy current hysteresis loss increase temperature rises. leakage current value noise filter installed inverter input side, contact corresponding filter manufacturer.
INSTALLATION WIRING
2.3.7 Instructions compliance with standards
(Since obtained approval Standards from products conforming Standards carry marks.)
Installation
above types have been approved products enclosure approval tests were conducted under following conditions. enclosure design, refer these conditions that ambient temperature inverter becomes 50°C less.
Inverter Type FR-A520-0.75K Control having size inverter size plus 100mm (3.94) 100mm (3.94) 50mm Control Size (Unit: (inches)) (8.27 14.17 6.89) (12.60 15.75 9.45) (13.78 23.62 9.45) Vent Hole Area (6.29 2.36) (top bottom) (5.12 2.76) (bottom) (12.99 2.76) (bottom) (bottom) (4.84 19.37) (bottom (4.84 4.96) (bottom (4.84 1.18) (top) (3.94 8.27) (bottom) (2.36 1.89) (bottom) (12.99 2.76) (4.84 4.96) (lower section ventilation ports) Cooling required Install cooling enclosure suck internal outside. (Fan flow: 1.72m3/min. more) Install cooling enclosure suck internal outside. (Fan flow: 3.44m3/min. more) Install cooling fans enclosure suck internal outside. (Fan flow: 3.24m3/min. more)
FR-A520-11K
FR-A520-22K
FR-A520-55K
(22.83 32.09 11.81) Inverter size plus 100mm (3.94) 100mm (3.94) 50mm (1.97)
FR-A540-5.5K
(12.20 18.11 8.66) (13.78 23.62 9.45) (21.65 26.18 11.81)
required. Install cooling fans enclosure suck internal outside. (Fan flow: 1.72m3/min. more) Install upper section panel that panel blown panel. (Fan capacity: 3.24m3/min. more)
FR-A540-22K
FR-A540-55K
Wiring power supply motor
UL-approved power supply round crimping terminals wire input output terminals inverter. Crimp terminals with crimping tool recommended terminal manufacturer.
Fuse
input side, Class fuses having ratings listed below:
Applicable Inverter Type FR-A520-0.4K FR-A520-0.75K FR-A520-1.5K FR-A520-2.2K FR-A520-3.7K FR-A520-5.5K FR-A520-7.5K FR-A520-11K FR-A520-15K FR-A520-18.5K FR-A520-22K FR-A520-30K FR-A520-37K FR-A520-45K FR-A520-55K Rating Applicable Inverter Type FR-A540-0.4K FR-A540-0.75K FR-A540-1.5K FR-A540-2.2K FR-A540-3.7K FR-A540-5.5K FR-A540-7.5K FR-A540-11K FR-A540-15K FR-A540-18.5K FR-A540-22K FR-A540-30K FR-A540-37K FR-A540-45K FR-A540-55K Rating
Short-circuit rating
Having been short-circuit test circuit whose peak current limited max., this inverter conforms this circuit.
Inverter Type 1.5kW 37kW (2HP 50HP) 45kW, 55kW (60, 75HP) 5,000 10,000
INSTALLATION WIRING
2.3.8 Instructions compliance with European standards
(The products conforming Voltage Directive carry mark.)
Directive
view transistorized inverters Directive transistorized inverter does function independently. component designed installation control with other equipment control equipment/device. Therefore, understand that Directive does apply directly transistorized inverters. this reason, place mark transistorized inverters themselves. (The mark placed inverters accordance with Voltage Directive.) European power drive manufacturers' organization (CEMEP) also holds this point view. Compliance understand that transistorized inverters themselves covered directly Directive. However, Directive applies machines/equipment into which transistorized inverters have been incorporated, these machines equipment must carry marks. Hence, prepared technical information "EMC Installation Guidelines" (information number BCNA21041-202) that machines equipment incorporating transistorized inverters conform Directive more easily. Outline installation method Install inverter using following methods: inverter with European Standard-compliant noise filter. wiring between inverter motor, shielded cables them metal piping ground cables inverter motor sides with shortest possible distance. Insert line noise filter ferrite core into power control lines required. Full information including European Standard-compliant noise filter specifications written technical information "EMC Installation Guidelines" (information number BCN-A21041-202). Please contact your sales representative.
Voltage Directive
view transistorized inverters Voltage Directive Transistorized inverters covered Voltage Directive. Compliance have self-confirmed inverters products compliant Voltage Directive place mark inverters. Outline instructions 400V class inverters, rated input voltage range three-phase, 380V 415V, 50Hz/60Hz. Connect equipment earth securely. earth leakage circuit breaker electric shock protector without connecting equipment earth. Wire earth terminal independently. connect more cables terminal.) input side, recommended no-fuse breaker magnetic contactor which conform Standard. inverter under conditions overvoltage category contamination level less forth IEC664. meet overvoltage category insert standard-compliant isolation transformer surge suppressor input inverter. meet contamination level install inverter control protected against ingress water, oil, carbon, dust, etc. (IP54 higher). input output inverter, cables type size forth EN60204 Appendix operating capacity relay outputs (terminal symbols should 30VDC, 0.3A. (The relay outputs basically isolated from inverter's internal circuitry.) Details given technical information "Low Voltage Directive Conformance Guide" (information number BCN-A21041-203). Please contact your sales representative.
INSTALLATION WIRING
2.3.9 Earthing version)
Earthing Earth Leakage Current
Purpose Earthing Electrical equipment usually Earthing Terminal, this must connected earth before using equipment. protection, electric circuits normally housed inside insulated case. However impossible manufacture insulating materials that prevent current from leaking across them, therefore function earth (safety earth) prevent electric shocks when touching case. There however, another important earthing function, which prevent equipment that uses very weak signals (Audio equipment, sensors, transducers, etc.) micro processors from being affected Radio Frequency Interference, (RFI) from external sources. Points remember when Earthing detailed above there entirely different types earthing attempt same earth both will lead problems. necessary separate "safety" earthing yellow/green wire prevent electric shocks) from "FRI" earthing braided wire strap counter radio noise). inverter output voltage does take form sine wave modulated pulse wave form causing "noisy" leakage current capacitance insulation. same type leakage current will occur motor charging discharging insulation from high frequency wave form. This trend becomes more pronounced with higher carrier frequencies. solve this problem necessary separate "dirty" earthing inverter motor installations "clean" earting equipment such sensors, computers audio equipment.
Earthing methods
main types earth 1-To prevent electrical shocks Yellow green cable 2-To prevent induced malfunction Braided strap important make clear distinction between these two, keep them separate following measures below. When possible earth inverter independently other equipment. independent earthing possible, common earthing point. Avoid connecting earthing wires together particularly high power equipment such motors inverters. Independent earthing should always used between sensitive equipment inverters.
Inverter Other equipment Inverter Other equipment Inverter Other equipment
Independent grounding
common grounding
Grounding wire other equipment
Safety earths should 400V duty Special class less 200V duty Class less
INSTALLATION WIRING
safety earth should thick possible, minimum thickness stated below table. earthing point should close inverter possible, wire short possible. earth should braided strap with 10mm minimum cross sectional area, short possible. earths should away from input output cables (particularly equipment sensitive RFI) possible, distance where they parallel should kept minimum. Design prevention before installation.
(Unit: Motor Size 3.7kW less 5.5kW, 7.5kW 11kW 15kW 18.5kW 37kW 45kW, 55kW Earth Wire Size 400V Class
CHAPTER OPERATION
This chapter provides basic "operation" this product. Always read this chapter before using equipment.
Pre-Operation Information. Operation
CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER APPENDICES
OUTLINE INSTALLATION WIRING OPERATION PARAMETERS PROTECTIVE FUNCTIONS SPECIFICATIONS OPTIONS
Pre-Operation Information
OPERATION
OPERATION Pre-Operation Information
3.1.1 Devices parts prepared operation
inverter operated "external operation mode", operation mode", "combined operation mode" "communication operation mode". Prepare required instruments parts according operation mode.
External operation mode (factory setting)
inverter operated under control external operation signals (frequency setting potentiometer, start switch, etc.) connected terminal block. With input power switch start signal (STF, STR) start operation. Preparation
Start switch Potentiometer Inverter DU04 PU04
Start signal Switch, relay, etc. Frequency setting signal 10V, 20mA signals from potentiometer outside
inverter Note: Both start signal frequency setting signal required inverter.
operation mode
inverter operated from keypad (FR-DU04/FR-PU04). This mode does require operation signals connected useful immediate start operation. Preparation
Inverter DU04 PU04
Operation unit.Operation panel (FR-DU04), parameter unit (FR-PU04) Connection cable prepared operation unit away from inverter.
FR-CB2 (option) following connector cable available market: Connector RJ45 connector Cable Cable conforming EIA568 (e.g. 10BASE-T cable)
External/PU combined operation mode
inverter operated with external operation operation modes combined following ways: start signal with external signal frequency setting signal from start signal with command (FR-DU04/FR-PU04) frequency setting signal with external frequency setting potentiometer. "operation mode selection".
Inverter
Potentiometer Start switch
OPERATION
Preparation
Start signal .Switch, relay, etc. (for Frequency setting signal 10V, 20mA signals from potentiometer outside Operation unit.Operation panel (FR-DU04), parameter unit (FR-PU04) Connection cable prepared operation unit away from inverter
FR-CB2 (option) following connector cable available market: Connector RJ45 connector Cable Cable conforming EIA568 (e.g. 10BASE-T cable) Combined operation mode Change setting "operation mode selection" follows:
Setting Description Running frequency setting Start signal (FR-DU04/FR-PU04) Terminal signal Direct setting [UP/DOWN] setting Parameter unit Terminal signal 5VDC across [FWD] 10VDC across [REV] 20mADC across Multi-speed selection (Pr. 239) frequency (Pr.
inverter (for
Communication operation mode
Communication operation performed connecting personal computer connector with RS-485 communication cable. inverter setup software available FR-A500 inverter start-up support software package. Preparation
Connection cable .Connector
Cable
Personal computer
RJ45 connector Cable conforming EIA568 (e.g. 10BASE-T cable)
<Inverter setup software operating environment>
Windows 3.1, Windows RAM. more Floppy disk drive. more inch floppy disk drives Mouse. Mouse connectable personal computer
OPERATION
3.1.2 Power
Before switching power check following:
Installation check
Make sure that inverter installed correctly correct place. (Refer page Wiring check Make sure that main control circuits wired correctly. Make sure that options peripheral devices selected connected correctly. (Refer page
Switch power
Power-on complete when POWER lamp correctly operation panel (FR-DU04) displays correct data.
3.1.3 Parameter check
inverter designed perform simple variable-speed operation with factory settings parameters. necessary parameters according load operation specifications. operation panel (FR-DU04) set, change confirm parameter values. full information parameters, refer "CHAPTER PARAMETERS" (page 57).
Operation panel (FR-DU04)
With operation panel (FR-DU04), running frequency, monitor operation command display, parameters, display error, copy parameters. Names functions operation panel (FR-DU04)
FR-DU04
Display digits CONTROL PANEL Unit indication (frequency) (current) (voltage)
Operation status indication
[MODE]
MODE
STOP RESET
[Operation command] keys [REV] (reverse rotation) [FWD] (forward rotation)
[SET]
[STOP/RESET]
[MODE] [SET] [UP/DOWN] key) [REV] [FWD] [STOP/RESET]
Description select operation mode setting mode. determine frequency parameter setting.
Used increase decrease running frequency consecutively. Hold down this change frequency. Press this setting mode change parameter setting consecutively.
Used give reverse rotation command. Used give forward rotation command.
Used stop operation. Used reset inverter when output stopped protective function activated (major fault).
OPERATION
Monitor display changed pressing [MODE]
zMonitoring mode
FR-DU04
CONTROL PANEL
zFrequency setting mode (Note)
FR-DU04
MODE
CONTROL PANEL
zParameter setting mode
FR-DU04
CONTROL PANEL
zOperation mode
FR-DU04
MODE
CONTROL PANEL
zHelp mode
FR-DU04
MODE
CONTROL PANEL
MODE
MODE
Note: frequency setting mode displayed only operation mode.
operation
Monitoring mode Operation command indications monitoring mode indicate external operation. indicate operation. Both indicate PU/external combined operation mode. monitor display also changed during operation.
zFrequency monitor
FR-DU04
CONTROL PANEL
zCurrent monitor
FR-DU04
CONTROL PANEL
zVoltage monitor
FR-DU04
CONTROL PANEL
zAlarm monitor
Alarm present
FR-DU04
CONTROL PANEL
Alarm absent
MODE
Frequency setting mode (Note
Note: Hold down [SET] marked more than seconds change current monitor power-on monitor. Hold down [SET] marked more than seconds display four errors including most recent one. Shifts parameter setting mode when external operation mode. Frequency setting mode Used running frequency operation mode.
frequency monitor
MODE
zSet frequency change
FR-DU04
CONTROL PANEL
zSet frequency write
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Press
MODE
change frequency.
Parameter setting mode
OPERATION
Parameter setting mode parameter value either updating parameter number setting value digit-by-digit using [UP/DOWN] key. write setting, change press [SET] seconds. (factory setting) "operation mode selection" select operation mode.
zParameter number change
FR-DU04
CONTROL PANEL
zSetting change
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
zSetting write Press sec. FR-DU04
Flicker
CONTROL PANEL
FR-DU04
CONTROL PANEL
Press
MODE
Press
MODE
change parameter number. Simultaneous input
change setting.
zhanging parameter number
Most significant digit flickers Middle digit flickers Least significant digit flickers
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Operation mode
Operation mode
zExternal operation
FR-DU04
CONTROL PANEL
operation
FR-DU04
CONTROL PANEL
operation
FR-DU04
CONTROL PANEL
MODE
MODE
MODE
Help mode
Help mode
FR-DU04
CONTROL PANEL
zAlarm history
zAlarm history
clear
zParameter clear
zAll clear
zUser clear
zSoftware version
read
MODE
Monitoring mode
OPERATION
Alarm history
Four past alarms displayed with [UP/DOWN] key. ("." appended most recent alarm.)
E.HIS
Shows alarm. (When alarm exists, displayed.)
Alarm display
Frequency alarm occurrence displayed.
Alarm history clear
Clears alarm history.
Flicker
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Cancel
Parameter clear
Initialises parameter values factory settings. calibration values initialized. (Parameter values cleared setting "parameter write disable selection).)
Flicker
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Cancel
clear
Initialises parameter values calibration values factory settings.
Flicker
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Cancel
User clear
Initialises user-set parameters. other parameters initialized factory settings.
Flicker
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Cancel
OPERATION
Copy mode using operation panel (FR-DU04), parameter values copied another inverter (only FR-A500 series). Operation procedure After reading parameter values from copy source inverter, connect operation panel copy destination inverter, write parameter values. After writing parameters inverter copy destination, always reset inverter, e.g. switch power once, before starting operation.
zParameter setting mode
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Press sec.
(Note
Press sec.
(Note
Press sec.
(Note
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
zParameter read
zParameter write
After writing parameters, always reset inverter before operation.
zParameter verify
Connect copy destination inverter.
Note: While copy function being activated, monitor display flickers. display returns lit-up state completion copy function. read error occurs during parameter read, "read error (E.rE1)" displayed. write error occurs during parameter write, "write error (E.rE2)" displayed. data discrepancy occurs during parameter verify, corresponding parameter number "verify error (E.rE3)" displayed alternately. direct frequency setting frequency setting discrepant, "verify error (E.rE3)" flickers. ignore this display continue verify, press [SET] key. When copy destination inverter FR-A500 series, "model error (E.rE4)" displayed.
Reference: recommended read parameter values after completion parameter setting.
writing parameter values from operation panel fitted inverter after inverter replacement, parameter setup completed.
OPERATION
Parameter setting check
recommend following parameters user. them according operation specifications, load, etc. (Refer page 57.)
Parameter Number Name Maximum frequency Minimum frequency Acceleration time Deceleration time Second acceleration/deceleration time Second deceleration time Third acceleration/deceleration time Third deceleration time Electronic thermal relay Load pattern selection Applied motor 0-5V/0-10V selection terminal calibration terminal calibration Frequency setting voltage bias Frequency setting voltage gain Frequency setting current bias Frequency setting current gain Application Used maximum minimum output frequencies.
Used acceleration deceleration times.
Used current electronic overcurrent protection protect motor from overheat. Used select optimum output characteristics which match application load characteristics. Used thermal characteristics electronic overcurrent protection according motor used. Used select specifications frequency setting signal entered across terminal perform operation with voltage input signal. Used calibrate meters connected across terminals FM-SD AM-5. Used magnitude (slope) output frequency relative frequency setting signal 20mA desired.
Operation
OPERATION
Operation
3.2.1 Pre-operation checks
Before starting operation, check following: Safety Perform test operation after making sure that safety ensured machine should become control. Machine Make sure that machine free damage. Parameters parameter values match operating machine system environment. Test operation Perform test operation make sure that machine operates safely under light load frequency. After that, start operation.
OPERATION
3.2.2 External operation mode (Operation using external input signals)
Operation 60Hz
Step Description Power-on Operation mode check Switch power make sure that operation command indication "EXT" lit. lit, switch external operation mode.) Image
FR-DU04
CONTROL PANEL
Start Turn start switch (STF STR). operation status indication "FWD" "REV" flickers. Note: motor does start both forward reverse rotation switches turned both switches turned during operation, motor decelerates stop. Acceleration Constant speed Slowly turn potentiometer (frequency setting potentiometer) full clockwise. frequency shown display increases gradually 60.00Hz.
Forward rotation Reverse rotation
FR-DU04
CONTROL PANEL
FR-DU04
CONTROL PANEL
Deceleration Slowly turn potentiometer (frequency setting potentiometer) full counterclockwise. frequency shown display decreases gradually 0.00Hz. motor stops running. Stop Turn start switch (STF STR).
Forward rotation Reverse rotation
Stop
External operation
Keep start switch (STF STR) perform operation, switch stop. "jog frequency" "jog acceleration/deceleration". Select external operation mode. Switch signal. Keep start switch (STF STR) perform operation.
OPERATION
3.2.3 operation mode (Operation using operation panel (FR-DU04))
Operation 60Hz
While motor running, repeat following steps vary speed: Step Description Power-on Operation mode check Switch power make sure that operation command indication "PU" lit. lit, switch operation mode.) Image
Running frequency setting running frequency 60Hz. First, press [MODE] select frequency setting mode. Then, press [UP/DOWN] change setting, press [SET] write frequency. Start Press [FWD] [REV] key. motor starts running. monitoring mode automatically selected output frequency displayed.
(or)
FR-DU04
CONTROL PANEL
(or)
Stop Press [STOP] key. motor decelerated stop.
FR-DU04
CONTROL PANEL
operation
Hold down [FWD] [REV] perform operation, release stop. "jog frequency" "jog acceleration/deceleration". Select operation mode. Hold down [FWD] [REV] perform operation. motor remains stopped, check "starting frequency". motor will start setting lower than starting frequency.)
OPERATION
3.2.4 Combined operation mode (Operation using external input signals
When entering start signal from outside inverter setting running frequency from (Pr. external frequency setting signals PU's FWD, STOP keys accepted. Step Power-on Switch power Description Image
Operation mode selection "operation mode selection". combined operation mode selected operation status indication "EXT" "PU" lit.
FR-DU04
CONTROL PANEL
Start Turn start switch (STF STR). Note: motor does start both forward reverse rotation switches turned both switches turned during operation, motor decelerates (when "9999") stop. Running frequency setting Using parameter unit, running frequency 60Hz. operation command indication "REV" "FWD" lit. Select frequency setting mode make step setting.
Forward rotation Reverse rotation
FR-DU04
CONTROL PANEL
Note: Step setting changing frequency consecutively pressing [UP/DOWN] key. Hold down [UP/DOWN] change frequency. Stop Turn start switch (STF STR). motor stops running.
<Step setting>
FR-DU04
CONTROL PANEL
CHAPTER PARAMETERS
This chapter explains "parameters" this product. Always read instructions before using equipment.
Parameter List Parameter Function Details.
Note: making parameter settings, change functions contact input terminals JOG, open collector output terminals RUN, IPF, Therefore, signal names corresponding functions used description this chapter (except wiring examples). Note that they terminal names. Note: settings brackets refer "EC" version default settings.
CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER CHAPTER APPENDICES
OUTLINE INSTALLATION WIRING OPERATION PARAMETERS PROTECTIVE FUNCTIONS SPECIFICATIONS OPTIONS
Parameter List
PARAMETERS
PARAMETER Parameter List
Parameter List
Function
Parameter Number
Name Torque boost (Note Maximum frequency Minimum frequency Base frequency Multi-speed setting (high speed) Multi-speed setting (middle speed) Multi-speed setting (low speed) Acceleration time Deceleration time Electronic thermal relay injection brake operation frequency injection brake operation time injection brake voltage Starting frequency Load pattern selection (Note frequency acceleration/deceleration time input selection High-speed maximum frequency Base frequency voltage (Note Acceleration/deceleration reference frequency Acceleration/deceleration time increments Stall prevention operation level Stall prevention operation level double speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed input compensation Acceleration/deceleration pattern Regenerative function selection Frequency jump Frequency jump Frequency jump Frequency jump Frequency jump Frequency jump Speed display Up-to-frequency sensitivity Output frequency detection Output frequency detection reverse rotation Second acceleration/deceleration time Second deceleration time Second torque boost (Note Second (base frequency) (Note Second stall prevention operation current Second stall prevention operation frequency Second output frequency detection
Setting Range 120Hz 120Hz 400Hz 400Hz 400Hz 400Hz 3600 3600 500A 120Hz, 9999 8888 60Hz 400Hz 3600 400Hz 1000V, 8888, 9999 400Hz 200%, 9999 200%, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 9998 100% 400Hz 400Hz, 9999 3600 3600 9999 30%, 9999 400Hz, 9999 200% 400Hz, 9999 400Hz
Minimum Setting Increments 0.1% 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01 0.01 0.01A 0.01Hz 0.1% 0.01Hz 0.01Hz 0.01 0.01Hz 0.1V 0.01Hz 0.1% 0.1% 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.1% 0.01Hz 0.01Hz s/0.01 s/0.01 0.1% 0.01Hz 0.1% 0.01 0.01Hz
Factory Setting Version 6%/4%/3%/2% (Note 120Hz 60Hz 50Hz 60Hz 30Hz 10Hz s/15 (Note s/15 (Note Rated output current 4%/2% (Note 0.5Hz 120Hz 9999 8888 60Hz 50Hz 150% 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 150% 30Hz
Refer Page:
Standard operation functions
Basic functions
Second functions
Output terminal functions
PARAMETERS
Function Display functions Parameter Number Minimum Setting Increments 0.01Hz 0.01A Factory Setting Version 60Hz 50Hz Rated output current 9999 Refer Page:
DU/PU main display data selection level display data selection terminal function selection Frequency monitoring reference Current monitoring reference Restart coasting time Restart cushion time
400Hz 500A 9999
Additional function
Automatic restart functions
Remote setting function selection
Operation selection functions
Intelligent mode selection Reference intelligent mode Ref. intelligent mode accel. Ref. intelligent mode decel. Starting frequency elevator mode Retry selection Stall prevention operation level reduction starting frequency Number retries alarm occurrence Retry waiting time Retry count display erasure Special regenerative brake duty Applied motor frequency selection 0-5V/0-10V selection Filter time constant Reset selection/disconnected detection/PU stop selection Alarm code output selection Parameter write disable selection Reverse rotation prevention selection Operation mode selection Motor capacity Number motor poles Motor exciting current (Note Rated motor voltage Rated motor frequency Speed control gain Motor constant (R1) (Note Motor constant (R2) (Note Motor constant (L1) (Note Motor constant (L2) (Note Motor constant Online auto tuning selection Auto tuning setting/status V/F1 (first frequency) (Note V/F1 (first frequency voltage) (Note V/F2 (second frequency) (Note V/F2 (second frequency voltage) (Note V/F3 (third frequency) (Note V/F3 (third frequency voltage) (Note V/F4 (fourth frequency) (Note
500A, 9999 200%, 9999 200%, 9999 10Hz, 9999 400Hz 10,101 15%/0 30%/0% (Note 55kW, 9999 9999 9999 1000V 120Hz 200.0% 9999 9999 9999 9999 9999 400Hz, 9999 1000V 400Hz, 9999 1000V 400Hz, 9999 1000V 400Hz, 9999
0.01A 0.1% 0.1% 0.01Hz 0.01Hz 0.1% 0.01kW 0.1V 0.01Hz 0.1%
9999 9999 9999 9999 60Hz 50Hz 9999 9999 9999 200/400V (Note 60Hz 50Hz 100% 9999 9999 9999 9999 9999 9999 9999 9999 9999
Advanced magnetic flux vectorcontrol
0.01Hz 0.1V 0.01Hz 0.1V 0.01Hz 0.1V 0.01Hz
5-point flexible characteristics
Parameter List
Name
Setting Range
PARAMETERS
Function 5-point flexible characteristics Parameter Number Third functions Backlash Minimum Setting Increments 0.1V 0.01Hz 0.1V s/0.01 s/0.01 0.1% 0.01Hz 0.1% 0.01Hz 0.01Hz 0.1% 0.1% 0.1% 0.01% 0.01 0.01Hz 0.01Hz 0.01Hz Factory Setting Version 9999 9999 9999 9999 9999 150% 9999 9999 9999 100% 9999 9999 9999 9999 1.00Hz 1.00Hz Refer Page:
Parameter List
Name V/F4 (fourth frequency voltage) (Note V/F5 (fifth frequency) (Note V/F5 (fifth frequency voltage) (Note Third acceleration/deceleration time Third deceleration time Third torque boost (Note Third (base frequency) (Note Third stall prevention operation current Third stall prevention operation frequency Third output frequency detection Station number Communication speed Stop length/data length Parity check presence/absence Number communication retries Communication check time interval Waiting time setting presence/absence selection action selection proportional band integral time Upper limit Lower limit action point operation differential time Commercial power supply-inverter switch-over sequence output terminal selection switch-over interlock time Start waiting time Commercial power supply-inverter switch-over selection alarm occurrence Automatic inverter-commercial power supply switch-over frequency Backlash acceleration stopping frequency (Note Backlash acceleration stopping time (Note Backlash deceleration stopping frequency (Note Backlash deceleration stopping time (Note
Setting Range
1000V 400Hz, 9999 1000V 3600 9999 3600 9999 30.0%, 9999 400Hz, 9999 200% 400Hz 400Hz, 9999 (data length (data length 9999 999.8 9999 150ms, 9999 0,1,2 1000%, 9999 3600 9999 100%, 9999 100%, 9999 100% 0.01 10.00 9999 100.0 100.0 60.00Hz, 9999 400Hz 400Hz
Display
Commercial power supplyinverter switch-over
control
Communication functions
Speed setting switch-over
102, 104, 106, 108,
Additional functions
Stall prevention level input Stall prevention level input
200% 200%
0.1% 0.1%
150% 200%
PARAMETERS
Function Current detection Parameter Number Additional function Minimum Setting Increments 0.1% 0.1% 0.01 Factory Setting Version 150% 5.0% Refer Page:
Output current detection level Output current detection period Zero current detection level Zero current detection period Voltage reduction selection during stall prevention operation activated condition Stall prevention operation selection signal waiting time terminal function selection
200% 200.0% 9999
functions
User group read selection
Automatic restart after instantaneous power failure
Automatic restart after instantaneous power failure selection First cushion time restart First cushion voltage restart Restart stall prevention operation level Watt-hour meter clear Actual operation hour meter clear User group registration User group deletion User group registration User group deletion terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection terminal function selection User's initial value setting
100% 200% 999, 9999 999, 9999 9999 9999 9999 9999 9999 9999 9999 199, 9999 199, 9999 199, 9999 199, 9999 199, 9999 199, 9999 999, 9999
0.1% 0.1%
150%
User functions
Initial monitor
Terminal assignment functions
Additional function
Parameter List
Name
Setting Range
PARAMETERS
Function Parameter Number Minimum Setting Increments 0.1Hz Minute second 0.1Hz Minute second 0.1Hz Minute second 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz Factory Setting Version 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 9999 Refer Page:
Parameter List
Name Programmed operation minute/second selection Program
Setting Range Minute, second Hour, minute 0-2: Rotation direction 0-400, 9999: Frequency 0-99.59: Time 0-2: Rotation direction 0-400, 9999: Frequency 0-99.59: Time 0-2: Rotation direction 0-400, 9999: Frequency 0-99.59: Time 99.59 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999 400Hz, 9999
Programmed operation
Program
Program Timer setting Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Multi-speed setting (speed Soft-PWM setting Cooling operation selection
Selection Additional Stop selection Power failure stop function functions Multi-speed operation function function function
Stop selection
9999
9999<
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