TRANSISTORIZED INVERTER FR-S500 FR-S500E-EC TRANSISTORIZED INVERTER INSTRUCTION MANUAL (BASIC) HEAD OFFICE:MITSUBISHI DENKI BLDG MARUNOUCHI TOKYO 100-8310 A IB(NA)-0600210ENG-A (0409) MDOC Printed in Japan Specifications subject to change without notice. INSTRUCTION MANUAL (BASIC) FR-S540E-0.4K to 3.7K-EC FR-S520SE-0.2K to 1.5K-EC Thank you for choosing this Mitsubishi transistorized inverter. If this is the first time for you to use the FR-S500 series, please read through this instruction manual (basic) carefully and use the inverter safely. If you are going to use the inverter for higher-level applications, the FR-S500 instruction manual (detailed) [IB(NA)-0600211ENG] is separately available from where you purchased the inverter or a Mitsubishi sales representative. CONTENTS 1 2 3 CONNECTION OF PERIPHERAL DEVICES ............................................. 2 4 RUN AND OPERATION............................................................................ 14 5 1.1 Basic configuration ...................................................................................... 2 1 INSTALLATION METHOD.......................................................................... 4 2.1 Installation of the inverter............................................................................. 4 SPECIFICATIONS OF WIRING AND TERMINALS ................................... 5 3.1 Terminal connection diagram ...................................................................... 5 3.2 Main circuit................................................................................................... 6 3.3 Control circuit............................................................................................... 9 4.1 Setting the frequency to perform operation (example: performing operation at 30Hz) ................................................. 16 4.2 Using the setting dial like a potentiometer to perform operation................ 17 4.3 Setting the parameters .............................................................................. 18 4.4 Clearing the parameters ............................................................................ 20 4.5 Monitoring the output current..................................................................... 21 4.6 Adjusting the current amount for frequency setting signal (example: performing operation at 30Hz) .................................................................. 22 ADJUSTMENT OF THE FREQUENCY SETTING POTENTIOMETER AND INDICATOR...................................................... 24 5.1 Changing the output frequency setting of the frequency setting potentiometer (bias and gain of frequency setting voltage (current)) .............................. 25 5.2 Adjustment (calibration) of the frequency meter (indicator) ....................... 28 6 FUNCTION LIST ....................................................................................... 29 7 ERRORS AND PROTECTIVE FUNCTIONS ............................................ 45 6.1 Basic function parameter list...................................................................... 29 6.2 Explanation of the basic function parameters............................................ 30 6.3 Extended function parameter list ............................................................... 32 7.1 About errors (definitions) ........................................................................... 45 7.2 To know the operating status at the occurrence of alarm (only when FR-PU04 is used).................................................................. 48 7.3 Correspondence between digital and actual characters............................ 48 7.4 Resetting the inverter................................................................................. 48 7.5 Troubleshooting ......................................................................................... 49 7.6 Precautions for maintenance and inspection............................................. 52 8 SPECIFICATIONS .................................................................................... 63 9 OUTLINE DRAWINGS.............................................................................. 67 8.1 Ratings....................................................................................................... 63 8.2 Common specifications.............................................................................. 65 Appendix 1 Instructions for compliance with the European Directive 70 Appendix 2 Instructions for UL and cUL.............................................. 72 2 3 4 5 6 7 8 9 This instruction manual (basic) provides handling information and precautions for use of the equipment. Please forward this instruction manual (basic) to the end user. This section is specifically about safety matters Do not attempt to install, operate, maintain or inspect the inverter until you have read through this instruction manual (basic) and appended documents carefully and can use the equipment correctly. Do not use the inverter until you have a full knowledge of the equipment, safety information and instructions. In this instruction manual (basic), the safety instruction levels are classified into "WARNING" and "CAUTION". WARNING Assumes that incorrect handling may cause hazardous conditions, resulting in death or severe injury. CAUTION Assumes that incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause physical damage only. Note that even the CAUTION level may lead to a serious consequence according to conditions. Please follow the instructions of both levels because they are important to personnel safety. 1. Electric Shock Prevention WARNING While power is on or when the inverter is running, do not open the front cover. You may get an electric shock. Do not run the inverter with the front cover or wiring cover removed. Otherwise, you may access the exposed high-voltage terminals or the charging part of the circuitry and get an electric shock. Also, the inverter's ability to withstand earthquakes will deteriorate. Even if power is off, do not remove the front cover except for wiring or periodic inspection. You may access the charged inverter circuits and get an electric shock. Before starting wiring or inspection, check to make sure that the 3-digit LED inverter monitor is off, wait for at least 10 minutes after the power supply has been switched off, and check to make sure that there are no residual voltage using a tester or the like. This inverter must be earthed. Earthing must conform to the requirements of national and local safety regulations and electrical codes. (JIS, NEC section 250, IEC 536 class 1 and other applicable standards) Any person who is involved in the wiring or inspection of this equipment should be fully competent to do the work. Always install the inverter before wiring. Otherwise, you may get an electric shock or be injured. Perform setting dial and key operations with dry hands to prevent an electric shock. Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Otherwise, you may get an electric shock. Do not change the cooling fan while power is on. It is dangerous to change the cooling fan while power is on. When you have removed the front cover, do not touch the connector above the 3digit monitor LED display. Otherwise, you get an electrick shock. A-1 2. Fire Prevention CAUTION Mount the inverter on an incombustible surface. Installing the inverter directly on or near a combustible surface could lead to a fire. If the inverter has become faulty, switch off the inverter power. A continuous flow of large current could cause a fire. Do not connect a resistor directly to the DC terminals +, -. This could cause a fire. 3. Injury Prevention CAUTION Apply only the voltage specified in the instruction manual to each terminal to prevent damage, etc. Always connect to the correct terminal to prevent damage, etc. Always make sure that polarity is correct to prevent damage, etc. While power is on or for some time after power-off, do not touch the inverter as it is hot and you may get burnt. 4. Additional Instructions Also note the following points to prevent an accidental failure, injury, electric shock, etc. (1) Transportation and installation CAUTION Environment When carrying products, use correct lifting gear to prevent injury. Do not stack the inverter boxes higher than the number recommended. Ensure that installation position and material can withstand the weight of the inverter. Install according to the information in the instruction manual. Do not install or operate if the inverter is damaged or has parts missing. When carrying the inverter, do not hold it by the front cover or setting dial; it may fall off or fail. Do not stand or rest heavy objects on the inverter. Check the inverter mounting orientation is correct. Prevent other conductive bodies as screws and metal fragments or other flammable substance as oil from entering the inverter. As the inverter is a precision instrument, do not drop or subject it to impact. Use the inverter under the following environmental conditions: This could cause the inverter damage. Ambient -10°C to +50°C (non-freezing) Temperature Ambient humidity 90%RH maximum (non-condensing) Storage -20°C to +65°C * temperature Indoors (free from corrosive gas, flammable gas, oil mist, Atmosphere dust and dirt) Maximum 1000m above sea level for standard operation. Altitude/ After that derate by 3% for every extra 500m up to 2500m vibration (91%). 5.9m/s2 or less (conforming to JIS C 60068-2-6) *Temperatures applicable for a short time, e.g. in transit. A-2 (2) Wiring CAUTION Do not fit capacitive equipment such as power factor correction capacitor, radio noise filter (option FR-BIF(-H)) or surge suppressor to the output of the inverter. The connection orientation of the output cables U, V, W to the motor will affect the direction of rotation of the motor. (3) Trial run CAUTION Check all parameters, and ensure that the machine will not be damaged by a sudden start-up. When the load GD2 is small (at the motor GD or smaller) for 400V from 1.5K to 3.7K, the output current may vary when the output frequency is in the 20Hz to 30Hz range. If this is a problem, set the Pr.72 "PWM frequency selection" to 6kHz or higher. (When setting the PWM to a higher frequency, check for noise or leakage current problem and take countermeasures against it.) (4) Operation WARNING When you have chosen the retry function, stay away from the equipment as it will restart suddenly after an alarm stop. The [STOP] key is valid only when the appropriate function setting has been made. Prepare an emergency stop switch separately. Make sure that the start signal is off before resetting the inverter alarm. A failure to do so may restart the motor suddenly. The load used should be a three-phase induction motor only. Connection of any other electrical equipment to the inverter output may damage the equipment. Do not modify the equipment. Do not perform parts removal which is not instructed in this manual. Doing so may lead to fault or damage of the inverter. A-3 CAUTION The electronic thermal relay function does not guarantee protection of the motor from overheating. Do not use a magnetic contactor on the inverter input for frequent starting/stopping of the inverter. Use a noise filter to reduce the effect of electromagnetic interference. Otherwise nearby electronic equipment may be affected. Take measures to suppress harmonics. Otherwise power supply harmonics from the inverter may heat/damage the power capacitor and generator. When a 400V class motor is inverter-driven, please use an insulation-enhanced motor or measures taken to suppress surge voltages. Surge voltages attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor. When parameter clear or all clear is performed, reset the required parameters before starting operations. Each parameter returns to the factory setting. The inverter can be easily set for high-speed operation. Before changing its setting, fully examine the performances of the motor and machine. In addition to the inverter's holding function, install a holding device to ensure safety. Before running an inverter which had been stored for a long period, always perform inspection and test operation. (5) Emergency stop CAUTION Provide a safety backup such as an emergency brake which will prevent the machine and equipment from hazardous conditions if the inverter fails. When the breaker on the inverter primary side trips, check for the wiring fault (short circuit), damage to internal parts of the inverter, etc. Identify the cause of the trip, then remove the cause and power on the breaker. When any protective function is activated, take the appropriate corrective action, then reset the inverter, and resume operation. (6) Maintenance, inspection and parts replacement CAUTION Do not carry out a megger (insulation resistance) test on the control circuit of the inverter. (7) Disposing of the inverter CAUTION Treat as industrial waste. (8) General instructions Many of the diagrams and drawings in this instruction manual (basic) show the inverter without a cover, or partially open. Never operate the inverter in this manner. Always replace the cover and follow this instruction manual (basic) when operating the inverter. A-4 Product Checking and Parts Identification Unpack the inverter and check the capacity plate on the front cover and the rating plate on the inverter side face to ensure that the product agrees with your order and the inverter is intact. Parts and name plate Rating plate Operation panel Inverter type Input rating Output rating Front cover Serial number Capacity plate Inverter type Wiring cover FR-S540E-0.4K-EC FR-S540E-0.4K-EC XXXXXX Inverter type Serial number FR - S540E - 0.4 K - EC Voltage class Symbol S540E Three-phase 400V class S520SE Single-phase 200V class Inverter capacity "kW" Removal and reinstallation of the front cover Remove the front cover by pulling it toward you in the direction of arrow. To reinstall, match the cover to the FR-S520SE-0.2K to 0.75K-EC inverter front and install it straight. FR-S540E-0.4K to 3.7K-EC FR-S520SE-1.5K-EC Removal and reinstallation of the wiring cover The cover can be removed easily by pulling it toward you. To reinstall, fit the cover to the inverter along the guides. Wiring cover RS-485 communication connector When using the RS-485 connector to wire the cable, you can cut off the tab of the wiring cover to wire it. (Cutting off Tab the tab will provide protective structure IP10.) CAUTION The connector above the operation panel is for manufacturer use. Do not touch it as doing so may cause an electric shock. 1 Basic configuration 1. CONNECTION OF PERIPHERAL DEVICES 1.1 Basic configuration Power supply Use within the permissible power supply specifications of the inverter. (Refer to page 63.) No-fuse breaker or earth leakage circuit breaker The breaker must be selected carefully since an inrush current flows in the inverter at power on. Magnetic contactor Install for your safety. Do not use this magnetic contactor to start and stop the inverter. Doing so will cause the inverter life to be shorten. (Refer to page 13.) (NFB) or (ELB) (MC) Installation of a reactor A reactor must be used when the power factor is to be improved or the inverter is installed near a large supply system (500kVA or more and wiring distance within 10 m). Make the selection carefully. AC reactor (FR-BAL) Earth Earth DC reactor (FR-BEL) Inverter The life of the inverter is influenced by ambient temperature. Check the ambient temperature. Epecially when mounting the inverter inside an enclosure, take cautions of the ambient temperature. (Refer to page 66.) Wrong wiring might lead to damage of the inverter. The control signal wires must be kept fully away from the main circuit to protect them from noise. (Refer to page 5.) Devices connected to the output Do not install a power factor correction capacitor, surge suppressor or radio noise filter on the output side of the inverter. When installing a no-fuse breaker on the output side of the inverter, contact each manufacturer for selection of the no-fuse breaker. Earth To prevent an electric shock, always earth the motor and inverter. For reduction of induction noise from the power line of the inverter, it is recommended to wire the earth cable by returning it to the earth terminal of the inverter. (For details of noise reduction techniques, refer to the instruction manual (detailed).) 2 Basic configuration Selection of peripheral devices (selection changes with the power input specifications of the inverter) 1) Three-phase 400V power input No-fuse Breaker Magnetic (NFB *1, 4) or Contactor Power Factor Power Factor Improving AC Improving DC Earth Leakage (MC) Reactor Reactor Circuit Breaker (Refer to (ELB) (*2, 4) page 13) Motor Output (kW) Applied Inverter Type 0.4 FR-S540E-0.4K-EC 30AF/5A S-N10 0.75 FR-S540E-0.75K-EC 30AF/5A S-N10 1.5 FR-S540E-1.5K-EC 30AF/10A S-N10 2.2 FR-S540E-2.2K-EC 30AF/15A S-N10 3.7 FR-S540E-3.7K-EC 30AF/20A S-N20, S-N21 FR-BALH0.4K FR-BALH0.75K FR-BELH0.4K FR-BELH0.75K FR-BALH1.5K FR-BALH2.2K FR-BELH1.5K FR-BELH2.2K FR-BALH3.7K FR-BELH3.7K No-fuse Breaker Magnetic (NFB *1, 4) or Contactor Power Factor Power Factor Improving AC Improving DC Earth Leakage (MC) Circuit Breaker (Refer to Reactor (*3) Reactor (*3) (ELB) (*2, 4) page 13) Motor Output (kW) Applied Inverter Type 0.2 FR-S520SE-0.2K-EC 30AF/10A 0.4 FR-S520SE-0.4K-EC 30AF/10A 0.75 FR-S520SE-0.75K-EC 30AF/15A 1.5 FR-S520SE-1.5K-EC 30AF/20A S-N10 S-N20, S-N21 S-N20, S-N21 S-N20, S-N21 FR-BAL-0.4K FR-BEL-0.4K FR-BAL-0.75K FR-BEL-0.75K FR-BAL-1.5K FR-BEL-1.5K FR-BAL-2.2K FR-BEL-2.2K *1. •Select the NFB according to the inverter power supply capacity. •Install one NFB per inverter. NFB INV IM NFB INV IM *2. For installations in the United States or Canada, the circuit breaker must be inverse time or instantaneous trip type. *3. The power factor may be slightly lower. *4. When the breaker on the inverter primary side trips, check for the wiring fault (short circuit), damage to internal parts of the inverter, etc. Identify the cause of the trip, then remove the cause and power on the breaker. 3 CONNECTION OF PERIPHERAL DEVICES 1 2) Single-phase 200V power input Installation of the inverter 2. INSTALLATION METHOD 2.1 Installation of the inverter Enclosure surface mounting Encasing multiple inverters Fix the front cover and wiring cover after removing them. When containing two or more inverters, install them in parallel and provide cooling measures. Leave enough clearances and provide cooling measures. Install the inverter under the following conditions. Ambient temperature and humidity Vertical mounting Clearances 1cm or more Vertical Temperature: -10°C to 50°C Humidity: 90%RH maximum Measurement position 5cm 5cm Inverter 5cm Measurement position 10cm or more 10cm or more 1cm or more These clearances are also necessary for changing the cooling fan. (The 1.5K or more is provided with a cooling fan.) Inverter consists of precision mechanical and electronic parts. Never install or handle it in any of the following conditions as doing so could cause an operation fault or failure. Direct sunlight Vertical mounting (when mounted inside enclosure) Vibration (5.9m/s2 or more) Transportation by holding front cover or dial 4 High temperature, high humidity Horizontal placement Oil mist, flammable gas, corrosive gas, fluff, dust, etc. Mounting to combustible material Terminal connection diagram 3. SPECIFICATIONS OF WIRING AND TERMINALS 3.1 Terminal connection diagram Three-phase 400V power input Inverter L1 L2 L3 Contact input common 24VDC power supply PC Take care not to short terminals PC-SD. Forward rotation start Control input Reverse rotation start signals High speed (No voltage Multi-speed Middle speed selection input allowed) Low speed External transistor common Contact input common (sink) + STF STR RH RM RL - *3 *3 *3 *3 *4 A *4 B *4 C SD 2 Alarm output SE Open collector output common 10 (+5V) 3 Earth Power factor improving DC reactor (FR-BEL: Option) Jumper: Remove this jumper when FR-BEL is connected. *4 RUN Running Frequency setting signals (Analog) Frequency setting potentiometer 1/2W1kΩ *2 Motor IM U V W P1 2 0 to 5VDC Selected Operation status output Open collector outputs 0 to 10VDC 1 Current input(-) 4 to 20mADC(+) 3 5 (Common) (+) Analog signal output (0 to 5VDC) (-) AM 4 (4 to 20mADC) SINK When using the current input as the frequency setting signal, set "4" in any of Pr. 60 to Pr. 63 (input terminal function selection), assign AU (current input selection) to any of terminals RH, RM, RL and STR and turn on the AU signal. *1 5 SOURCE RS-485 Connector Main circuit terminal Earth Control circuit terminal REMARKS *1. *2. *3. *4. You can switch the position of sink and source logic. Refer to the instruction manual (detailed) for details. When the setting potentiometer is used frequently, use a 2W1kΩ potentiometer. The terminal functions change with input terminal function selection (Pr. 60 to Pr. 63). (Refer to page 36.) (RES, RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, X14, X16, (STR) signal selection) The terminal function changes according to the setting of output terminal function selection (Pr. 64, Pr. 65). (Refer to page 37.) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y93, Y95, LF, ABC signal selection) CAUTION To prevent a malfunction due to noise, keep the signal cables more than 10cm away from the power cables. 5 SPECIFICATIONS OF WIRING AND TERMINALS NFB MC Three-phase AC power supply Main circuit Single-phase 200V power input NFB MC Power supply Motor L1 N U V W IM Earth REMARKS • To ensure safety, connect the power input to the inverter via a magnetic contactor and earth leakage circuit breaker or no-fuse breaker, and use the magnetic contactor to switch power on-off. • The output is three-phase 200V. 3.2 Main circuit 3.2.1 Explanation of main circuit terminals Terminal Terminal Name Description Symbol L1, L2, L3 (*1) AC power input Connect to the commercial power supply. U, V, W Inverter output Connect a three-phase squirrel-cage motor. +, − +, P1 Brake unit connection Connect the brake unit (BU), power regeneration common converter (FR-CV) or high power factor converter (FR-HC). Power factor Remove the jumper across terminals + - P1 and connect improving DC the optional power factor improving DC reactor (FRreactor BEL(-H)). connection Earth For earthing the inverter chassis. Must be earthed. *1. When using single-phase power input, terminals are L1 and N. 6 Main circuit 3.2.2 Terminal block layout 1) Three-phase 400V power input • FR-S540E-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-EC Jumper - + P1 L1 L2 L3 U V W IM Power supply Motor 2) Single-phase 200V power input • FR-S520SE-0.2K, 0.4K, 0.75K-EC • FR-S520SE-1.5K-EC Jumper L1 N - P1 + U V W - + Jumper P1 L1 N U V W IM Power supply IM Motor Power supply Motor 7 SPECIFICATIONS OF WIRING AND TERMINALS 3 CAUTION •Make sure the power cables are connected to the L1, L2, L3 of the inverter. Never connect the power cable to the U, V, W of the inverter. (Phase need not be matched) •Connect the motor to U, V, W. At this time, turning on the forward rotation switch (signal) rotates the motor in the counterclockwise direction when viewed from the motor shaft. Main circuit 3.2.3 Cables, wiring length, and crimping terminals The following table indicates a selection example for the wiring length of 20m. 1) Three-phase 400V power input PVC Insulation Ter- TightCable Crimping Cable minal ening Applied Inverter Terminal AWG Screw Torque mm2 mm2 size N⋅m L1, L2, L3 U, V, W L1, L2, L3 U, V, W L1, L2, L3 U, V, W L1, L2, L3 U, V, W FR-S540E-0.4K M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5 to 3.7K-EC 2) Single-phase 200V power input PVC Insulation Termi- TightCable Crimping Cable nal ening Applied Inverter Terminal AWG Screw Torque mm2 mm2 size N⋅m L1, N U, V, W L1, N U, V, W L1, N U, V, W L1, N U, V, W FR-S520SE-0.2K M3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5 to 0.75K-EC FR-S520SE-1.5KM4 1.5 2-4 2-4 2 2 14 14 2.5 2.5 EC Wiring length 100m maximum. (50m maximum for the FR-S540E-0.4K-EC.) CAUTION •When the wiring length of the 0.2K of the single-phase 200V class and 0.4K and 0.75K of the three-phase 400V class is 30m or more, set the carrier frequency to 1kHz. •When automatic torque boost is selected in Pr. 98 "automatic torque boost selection (motor capacity)", the wiring length should be 30m maximum. (Refer to page 40.) 8 Control circuit 3.3 Control circuit Explanation of control circuit terminals Symbol Terminal Name Contact input Forward rotation STF start STR RH Multi-speed RM selection RL SD (*1) PC (*1) 10 External transistor common, Contact input common (sink) 24VDC power supply, Contact input common (source) Frequency setting power supply Turn on the STF signal to start forward rotation and turn it off to stop. When the STF and STR signals are turned on simultaneously, the stop command is given. Turn on the STR signal to start reverse rotation and The terminal turn it off to stop. Turn on the RH, RM and RL signals in functions change with input terminal appropriate combinations to select function selection multiple speeds. The priorities of the speed commands (Pr. 60 to Pr.63). are in order of jog, multi-speed setting (*3) (RH, RM, RL, REX) and AU. When connecting the transistor output (open collector output), such as a programmable controller (PLC), connect the negative external power supply for transistor output to this terminal to prevent a malfunction caused by undesirable currents.(*6) When sink logic has been selected, this terminal serves as a contact input common. Common to the contact input terminals (STF, STR, RH, RM, RL). This terminal can be used as a 0.1A 24VDC power supply across terminals PC-SD. 5VDC, Permissible load current 10mA. Inputting 0 to 5VDC (or 0 to 10V) provides the maximum output 2 Frequency setting Input signals Reverse rotation start Definition 4 5 Frequency setting frequency at 5V (10V) and makes input and output proportional. Switch between 5V and 10V using Pr. 73 "0-5V, 0-10V selection". (voltage signal) Input resistance 10kΩ. Maximum permissible input voltage 20V Input 4 to 20mADC. It is factory set at 0Hz for 4mA and at 50Hz for 20mA. Maximum permissible input current 30mA. Input resistance Frequency setting approximately 250Ω. Turn ON signal AU for current input. (current signal) Turning the AU signal on makes voltage input invalid. Use any of Pr. 60 to Pr. 63 (input terminal function selection) to set the AU signal. Frequency setting Common terminal for the frequency setting signals (terminal 2, 4) and indicator connection (terminal AM). (*6) input common 9 3 SPECIFICATIONS OF WIRING AND TERMINALS 3.3.1 Control circuit Communication Open collector Terminal Name A B C Alarm output RUN Inverter running SE Indicator Output signals Symbol Open collector common Analog signal AM output —— RS-485 connector Definition Changeover contact output indicates that the inverter protective function has activated and the output stopped. 230VAC 0.3A, 30VDC 0.3A. Alarm: discontinuity across B-C (continuity across A-C), Normal: continuity across B-C (discontinuity across A-C).(*5) Switched low when the inverter output frequency is equal to or higher than the starting frequency (factory set to 0.5Hz variable). Switched high during stop or DC injection brake operation. (*2) Permissible load 24VDC 0.1A (a voltage drop is 3.4V maximum when the signal is on) The function of the terminals changes according to the output terminal function selection (Pr. 64, Pr.65). (*4) Common terminal for inverter running terminal RUN. (*6) The output signal across terminals AM-5 is factory set to about 5VDC at 50Hz and is proportional to the corresponding output frequency. Frequency permissible load current 1mA Output signal 0 to 5VDC Using the parameter unit connection cable (FR-CB201 to 205), the parameter unit (FR-PU04) can be connected. Communication operation can be performed using RS-485. For details of RS-485 communication, refer to the separately available instruction manual (detailed). *1. Do not connect terminals SD and PC each other or to the earth. For source logic (factory setting), terminal PC acts as the common terminal of contact input. For sink logic, terminal SD acts as the common terminal of contact input. (Refer to the separately available instruction manual (detailed) for switching method.) *2. Low indicates that the open collector output transistor is on (conducts). High indicates that the transistor is off (does not conduct). *3. RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, RES, X14, X16, (STR) signal selection (Refer to page 36.) *4. RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y93, Y95, LF, ABC signal selection (Refer to page 37.) *5. To be compliant with the European Directive (Low Voltage Directive), the operating capacity of relay outputs (A, B, C) should be 30VDC 0.3A. *6. Terminals SD, SE and 5 are isolated from each other. Do not earth. 10 Control circuit 3.3.2 Arrangement and wiring of control circuit terminals PC SE RUN 10 2 5 4 SD SD STF STR RL RM RH AM Control circuit terminal block A B C Loosen the terminal screw and insert the cable into the Cable stripping size terminal. Screw size: M3 (A, B, C terminals), M2 (other than the above) Tightening torque: 0.5N•m to 0.6N•m (A, B, C terminals) 0.22N•m to 0.25N•m (other than the Wire the stripped cable after twisting it to prevent it from above) becoming loose. CAUTION In addition, do not solder it. Undertightening can cause cable disconnection or malfunction. Overtightening can cause a short circuit or malfunction due to damage to the screw or unit. Cable size: 0.3mm2 to 0.75mm2 Screwdriver: Small flat-blade screwdriver Tip thickness: 0.4mm Tip width: 2.5mm ABC terminals Other than the above 6mm 5mm CAUTION When using the bar terminal (without insulation sleeve), use care so that the twisted wires do not come out. SPECIFICATIONS OF WIRING AND TERMINALS 3 11 Control circuit 3.3.3 Connection to RS-485 connector (1) When connecting the parameter unit Use the optional FR-CB2 . When the parameter unit (FR-PU04) is used, STOP operation from the operation panel is not accepted. ( RESET is valid) (2) RS-485 communication Using the RS-485 connector, you can perform communication operation from a personal computer etc. By connecting the RS-485 connector to computers such as personal computer and FA with a communication cable, you can run/monitor the inverter and read/write parameter values using a user program. For further details, refer to the instruction manual (detailed). · Conforming standard: EIA-485 (RS-485) · Transmission format: Multi-drop link · Communication speed: Maximum 19200 bps · Overall extension: 500m CAUTION Do not plug the connector to a computer LAN board, fax modem socket, telephone modular connector etc. As they are different in electrical specifications, the inverter may be damaged. 12 Control circuit 3.3.4 Power-off and magnetic contactor (MC) (1) Inverter input side magnetic contactor (MC) On the inverter's input side, it is recommended to provide an MC for the following purposes. (Refer to page 3 for selection) 1) To release the inverter from the power supply when the inverter protective function is activated or the drive becomes faulty (e.g. emergency stop operation) 2) To prevent any accident due to an automatic restart at restoration of power after an inverter stop made by a power failure 3) To rest the inverter for an extended period of time The control power supply for inverter is always running and consumes a little power. When stopping the inverter for an extended period of time, powering off the inverter will save power slightly. 4) To separate the inverter from the power supply to ensure safe maintenance and inspection work The inverter's input side MC is used for the above purpose, select class JEM1038AC3 for the inverter input side current when making an emergency stop during normal operation. REMARKS The MC may be switched on/off to start/stop the inverter. However, since repeated inrush currents at power on will shorten the life of the converter circuit (switching life is about 100,000 times), frequent starts and stops must be avoided. Turn on/off the inverter start controlling terminals (STF, STR) to run/stop the inverter. NFB MC L1 L2 L3 U V W T (*1) Inverter *1. When the power supply is 400V class, install a step-down transformer. Operation ready ON OFF MC To motor A B C MC RA Start/Stop STF(STR) PC Operation MC OFF RA RA Inverter Start/Stop Circuit Example (2) Handling of output side magnetic contactor In principle, do not provide a magnetic contactor between the inverter and motor and switch it from off to on during operation. If it is switched on during inverter operation, a large inrush current may flow, stopping the inverter due to overcurrent shut-off. When an MC is provided for switching to the commercial power supply, for example, switch it on/off after the inverter and motor have stopped. 13 3 SPECIFICATIONS OF WIRING AND TERMINALS As shown on the right, always use the start signal Power (ON or OFF across terminals STF or STR-PC) supply to make a start or stop. 4. RUN AND OPERATION <Operation panel> The operation panel cannot be removed from the inverter. PU/EXT Key RUN indication Turns on/flickers* to indicate operation. PU indication ** Lit to indicate the PU operation mode. RUN PU PU EXT EXT RUN 3-digit monitor LED STOP RESET Shows the frequency, parameter number, etc. MODE SET EXT indication ** Used to switch between the PU and external operation mode.When using the external operation mode (operation using the separately connected frequency setting potentiometer and start signal), press this key to light up the EXT indication. (Change the Pr. 79 value to use the combined mode.) PU: PU operation mode EXT: External operation mode Lit to indicate the external operation mode. RUN Key Setting dial Used to give the forward rotation operation command. Use Pr. 17 to set reverse operation. (Setting dial: Mistubishi inverter's dial) Used to change the frequency setting and parameter values. This dial cannot be removed. STOP/RESET Key Used to stop operation or reset an alarm. MODE Key SET Key Used to change the setting mode. Used to define each setting. * RUN indication On: Indicates that forward rotation operation is being performed. Slow flickering (1.4s cycle): Indicates reverse rotation Fast flickering (0.2s cycle): Indicates that operation is not being performed but the RUN was pressed or the start command was given. ** PU/EXT indication Flickers slowly in the computer link operation mode. REMARKS • When the parameter unit (FR-PU04) is used, operation from the operation panel is not accepted. ( STOP RESET is valid) 14 <Basic operation> (factory setting) Monitor/frequency setting Return MODE Press MODE key. [Operation panel is used for operation] Frequency setting has PU SET been written and EXT completed!! Press Turn the Press and frequency flickers. PU/EXT setting dial SET key RUN Press to start. key. to match frequency. STOP Press to stop. RESET Parameter setting [Parameter setting change] PU EXT MODE Press MODE key. SET Press Turn the setting PU/EXT dial to match key. frequency. SET Turn the setting dial to change value. Alarm history Press SET key to complete setting. Press SET key to show present setting. After setting is completed, press the MODE once to show alarm history, or twice to show frequency setting screen. [Operation for displaying alarm history] Four past alarms can be displayed with the setting dial (The latest alarm is ended by ".".) When no alarm exists, is displayed. . MODE Press MODE key. RUN AND OPERATION 4 15 Setting the frequency to perform operation (example: performing operation at 30Hz) 4.1 Setting the frequency to perform operation (example: performing operation at 30Hz) POINT •Set "0" (setting dial frequency setting mode) in Pr. 53 "frequency setting operation selection". Display Operation RUN 1. Screen at power-on PU The monitor display appears. 2. 3. 4. EXT RUN PU Press the EXT to choose the PU operation mode. Turn the to show the frequency you want to set. Flickers for about 5s. PU EXT PU indication is lit. PU EXT Flickers for about 5s. While the value is flickering, press the SET to set the frequency. If you do not press the SET , the value flickers for about 5s and the display then returns to 0.0 (monitor display). At this time, return to "step 3" and set the frequency again. SET Flicker...Frequency setting complete!! 3s later 5. RUN After the value flickered for about 3s, the display returns to 0.0 (monitor display). Press the RUN to start operation. To 6. change the set frequency, perform the operation in above steps 3 and 4. (Starting from the previously set frequency.) STOP RESET 7. Press the STOP RESET to stop. RUN PU EXT RUN PU EXT Operation cannot be performed at the set frequency ... Why? Did you carry out step 4 within 5s after step 3? (Did you press the SET within 5s after turning the setting dial?) Setting of higher than 50Hz cannot be made ... Why? Check to see if the Pr. 1 "maximum frequency" setting is 50Hz. The frequency does not change by turning the setting dial ... Why? Check to see if the operation mode selected is the external operation mode. REMARKS Pressing the setting dial shows the set frequency. • The setting dial can also be used like a potentiometer to perform operation. (Refer to page 17.) 16 Using the setting dial like a potentiometer to perform operation 4.2 Using the setting dial like a potentiometer to perform operation POINT •Set "1" (extended function parameter valid) in Pr. 30 "extended function display selection". •Set "1" (setting dial potentiometer mode) in Pr. 53 "frequency setting operation selection". Operation example Changing the frequency from 0Hz to 50Hz during operation Operation 1. Display Mode/monitor check. Choose monitor/frequency monitor. The inverter must be in the PU operation mode. (Press the Pr. 30 must be set to "1". Pr. 53 must be set to "1". 2. 3. Press the RUN the inverter. PU EXT RUN ( MODE PU EXT .) RUN to start RUN PU EXT Turn the clockwise until "50.0" appears. The flickering frequency is the set frequency. You need not press the ) SET Flickers for 3s. . 4 17 RUN AND OPERATION REMARKS • If flickering "50.0" turns to "0.0", the Pr. 53 "frequency setting operation selection" setting may not be "1". • Independently of whether the inverter is running or at a stop, the frequency can be set by merely turning the dial. Setting the parameters 4.3 Setting the parameters 4.3.1 Example: Changing the Pr. 7 setting from "5s" to "10s" (For parameter details, refer to the instruction manual (detailed).) Display Operation 1. Confirm the RUN indication and RUN operation mode indication. The inverter must be at a stop. The inverter must be in the PU PU .) operation mode. (Press the EXT 2. Press the MODE to choose the parameter setting mode. until the desired 3. Turn the parameter number appears. Example: Pr. 7 "acceleration time" 4. Press the SET to read the currently set value. Example: "5" (factory setting) appears. PU EXT The parameter number read previously appears. MODE SET 5. Turn the until the desired value appears. Example: To change setting from "5" to "10". 6. Press the SET to set the value. SET Flicker...Parameter setting complete!! • By turning the , you can read another parameter. • Press the SET to show the setting again. • Press the SET twice to show the next parameter. After parameter setting is complete, press the MODE once to show the alarm history or twice to return to the monitor display. To change the setting of another parameter, perform the operation in above steps 3 to 6. Error display? • If write was performed with "1" set in Pr. 77 • If the operation panel does not have the write precedence • If write was performed during operation • If write was performed in the external operation mode Remarks • If the setting has not been changed, the value does not flicker and the next parameter number appears. • Either step 1 or 2 may be carried out first. • Convenient usage After carrying out steps 1 and 2 to choose the parameter setting mode, you can read a series of parameter numbers in due order every time you press the 18 SET . Setting the parameters 4.3.2 Example: Changing the Pr. 30 setting from "0" to "1" (The extended parameters are made valid by setting "1" in Pr. 30 "extended function display selection". Refer to page 32 for the extended function parameter list and to the instruction manual (detailed) for details.) Display Operation 1. Confirm the RUN indication and operation mode indication. The inverter must be at a stop. The inverter must be in the PU operation mode. (Press the 2. Press the MODE to choose the parameter setting mode. 3. Turn the appears. 4. Press the SET to read the currently set value. " " (factory setting) appears. until RUN PU PU EXT MODE (Pr. 30) 5. Turn the to change it to the set value of " ". 6. Press the SET to set the value. EXT .) The parameter number read previously appears. SET SET Flicker...Parameter setting complete!! • Press the SET • Press the SET 4 , you can read another parameter. to show the setting again. twice to show the next parameter. After parameter setting is complete, press the MODE once to show the alarm history or twice to return to the monitor display. To change the setting of another parameter, perform the operation in above steps 3 to 6. Error display? • If the operation panel does not have the write precedence • If write was performed during operation. • If write was performed in the external operation mode REMARKS If the setting has not been changed, the value does not flicker and the next parameter number appears. 19 RUN AND OPERATION • By turning the Clearing the parameters 4.4 Clearing the parameters POINT •The clear parameter CLr is an extended parameter. Set "1" in Pr. 30 and turn the dial to show it. (Refer to page 19.) •The parameters can be cleared by setting "1" in CLr "parameter clear". Operation Display 1. Confirm the RUN indication and operation mode indication. The inverter must be at a stop. The inverter must be in the PU operation mode. (Press the 2. Press the MODE to choose the parameter setting mode. 3. Turn the RUN PU EXT PU EXT .) The parameter number read previously appears. MODE until "CLr" appears. Pr. 30 must be set to "1" (For details, refer to steps 3 to 6 on page 19 .) 4. Press the 5. Turn 6. Press the to show "0" SET SET to change it to "1". SET . SET Flicker...Parameter setting complete!! , you can read another parameter. • By turning the • Press the SET to show Pr.0 ( ). CLr Setting 0 1 10 Definition Not executed. Parameter clear *1 (Calibration parameters C1 to C7 are not cleared.) All clear *2 (All set values including those of calibration parameters C1 to C7 are returned to factory settings.) *1. Parameters are not cleared when "1" is set in Pr. 77 "parameter write disable selection". *2. Pr. 75 "reset selection/PU stop selection", Pr. 38, Pr. 39, Pr. 53, Pr. 60 to Pr. 65, Pr. 99, maintenance parameters H1, H2, calibration parameters C1 to C7 and communication parameters n13, n 15 are not cleared. *3. Pr. 75 "reset selection/PU stop selection", maintenance parameter H1 "maintenance timer" and communication parameter n13 "PU display language selection" are not cleared. 20 Monitoring the output current 4.5 Monitoring the output current POINT The output current appears while the SET is pressed in the monitor mode. Display Operation 1. Press the MODE to choose the output frequency monitor mode. 2. Independently of whether the inverter is running in any operation mode or at a stop, the output current appears while the SET is pressed. SET (1.0A) Hold down 3. Release the SET to return to the output frequency monitor mode. Remarks When Pr. 52 = "1", the output current is displayed in the monitor mode and the output SET is pressed. 4 RUN AND OPERATION frequency appears while the 21 Adjusting the current amount for frequency setting signal (example: performing operation at 30Hz) 4.6 Adjusting the current amount for frequency setting signal (example: performing operation at 30Hz) POINT •Assign the AU signal to any of the terminal RH, RM, RL, or STR and turn on the AU signal. •Pr. 62 and Pr. 39 are extended function parameters. Set "1" in Pr. 30. (Refer to page 19.) •Set "2" (external operation mode) in Pr. 79 "operation mode" [Connection diagram] Inverter Motor NFB MC Three-phase AC power supply L1 L2 L3 STF STR AU signal (RH terminal) PC Forward rotation start Reverse rotation start Current input selection Current output frequency setting device (4 to 20mADC) U V W IM Earth 4 (positive) 5 (negative) [AU signal assignment] Assign the AU signal to any of the RL, RM, RH or STR terminal. (example) Assign the AU signal to the RH terminal. Set "4" (AU signal) in Pr. 62 "RH terminal function selection". Display Operation 1. Confirm the RUN indication and operation mode indication. The inverter must be at a stop. The inverter must be in the PU operation mode.(Press the RUN PU PU EXT .) The parameter number read previously appears. 2. Press the MODE to choose the parameter setting mode. 3. Turn the until EXT MODE (Pr. 62) appears. 4. Press the SET to read the currently set value. " " (factory setting) appears. SET 5. Turn the tochange it to the set valueof " ". 6. Press the the value. SET to set SET Flicker...AU signal assignment complete!! REMARKS • Refer to page 31, 34 for other parameters' setting. • Refer to page 36 for details of Pr. 62 "RH terminal function selection". 22 Adjusting the current amount for frequency setting signal (example: performing operation at 30Hz) [Adjust to output 30Hz at 20mA current input] Set "30Hz" in Pr. 39. Display Operation 7. Turn the 8. Press the 9. Turn the 10. Press the 11. Apply currents across terminals 4-5 of the inverter with a current output frequency setting potentiometer to turn on the start command (STF, STR). Operation starts at 30Hz. until SET (Pr. 39) appears. to show the currently set value. (50Hz) SET to change it to the set value of "30.0". (30Hz) SET SET to set the value. Flicker···30Hz output at 20mA current input setting complete! REMARKS • Set frequency at 4mA using calibration parameter C6 and adjust the indicator using calibration parameter C7. (Refer to page 42.) Factory Setting 50Hz ( Pr.39 ) Output frequency (Hz) (Across terminals 4-5) 20mA 0Hz 4mA ( C5 ) (20% C6 ) (100% C7 ) Frequency setting current signal RUN AND OPERATION 4 23 5. ADJUSTMENT OF THE FREQUENCY SETTING POTENTIOMETER AND INDICATOR Related parameters Parameter 38 39 C2 C3 C4 C5 C6 C7 Name Setting Range Factory Setting Frequency setting voltage gain frequency Frequency setting current gain frequency Frequency setting voltage bias frequency Frequency setting voltage bias Frequency setting voltage gain Frequency setting current bias frequency Frequency setting current bias Frequency setting current gain 1 to 120Hz 1 to 120Hz 0 to 60Hz 0 to 300% 0 to 300% 0 to 60Hz 0 to 300% 0 to 300% 50Hz 50Hz 0Hz 0% *1 96% *1 0Hz 20% *1 100% *1 *1. Settings may differ because of calibration parameters. Output frequency (Hz) (Across terminals 2-5) 0Hz ( C2 ) 0V 5V or 10V Pr.73 *2 (100% C4 ) (0% C3 ) Frequency setting voltage signal Output frequency (Hz) 50Hz ( Pr.39 ) 50Hz Factory setting ( Pr.38 ) Factory setting (Across terminals 4-5) 0Hz 20mA ( C5 ) 4mA (20% C6 ) (100% C7 ) Frequency setting current signal *2. Pr. 73 "0-5V/0-10V selection" changes the specifications of terminal "2". POINT •Bias setting for 0 to 5VDC (0 to 10VDC) input Use the calibration parameter C2, C3 for setting •Gain setting for 0 to 5VDC (0 to 10VDC) input Use Pr. 38, calibration parameter C4 for setting. •Bias setting for 4 to 20mADC input Use the calibration parameter C5, C6 for setting. •Gain setting for 4 to 20mADC input Use Pr. 39, calibration parameter C7 for setting. For 4 to 20mADC input, set "4" in any of Pr. 60 to Pr. 63 (input terminal function selection) and assign AU (current input selection) to any of terminals RH, RM, RL and STR, and turn on the AU signal. 24 Changing the output frequency setting of the frequency setting potentiometer (bias and gain of frequency setting voltage (current)) POINT Pr. 38, Pr. 39 and calibration parameters "C1 to C7" can be made to be read by setting "1" (extended function parameter valid) in Pr. 30 "extended function display selection". The bias/gain of the frequency setting voltage (current) may be adjusted in any of the following methods: (1) Changing the highest frequency (2) Adjusting the deviation of the highest frequency from the Pr. 38 (Pr. 39) setting (2)-1) Make adjustment with a voltage applied across terminals 2-5 (with a current flowing across terminals 4-5) (2)-2) Make adjustment at any point without a voltage applied across terminals 2-5 (without a current flowing across terminals 4-5) (For the setting method, refer to the instruction manual (detailed).) ADJUSTMENT OF THE FREQUENCY SETTING POTENTIOMETER AND INDICATOR 5.1 Changing the output frequency setting of the frequency setting potentiometer (bias and gain of frequency setting voltage (current)) 5 25 Changing the output frequency setting of the frequency setting potentiometer (bias and gain of frequency setting voltage (current)) Changing example When you want to use the 0 to 5VDC input frequency setting potentiometer to change the 5V-time frequency from 50Hz (factory setting) to 40Hz. POINT •Pr. 38 is an extended function parameter. Pr. 30 must be set to "1". (Refer to page 19.) •Change Pr. 38 "frequency setting voltage gain frequency" to 40Hz. (1) Changing the highest frequency Operation 1. 2. Display Confirm the RUN indication and operation mode indication. The inverter must be at a stop. The inverter must be in the PU operation mode. (Press the Press the MODE to choose the parameter setting mode. RUN PU EXT PU EXT ) MODE 3. Turn the until Pr. 38 "frequency setting voltage gain frequency" appears. The parameter number read previously appears. Pr. 30 must be set to "1" (Refer to steps 3 to 6 on page 19 for the parameter setting method.) 4. Press the SET to display SET the currently set value.(50Hz) 5. Turn the to change it to "40.0".(40Hz) 6. Press the the value. SET to set SET Flicker...Parameter setting complete!! By turning the , you can read another parameter. Press the SET to show the setting again. Press the SET twice to show the next parameter. The monitor/frequency setting indication cannot be changed to just 40Hz ...Why? The calibration parameter C4 "frequency setting voltage gain" value must be set. (Refer to page 27.) REMARKS To change the value to more than 50Hz, Pr. 1 "maximum frequency" must be set to more than 50Hz. 26 Changing the output frequency setting of the frequency setting potentiometer (bias and gain of frequency setting voltage (current)) Changing example Changing the calibration parameter C4 "frequency setting voltage gain" Display Operation 1. Confirm the RUN indication and operation RUN PU mode indication. The inverter must be at a stop. The inverter must be in the PU operation PU mode.(Press the EXT .) EXT The parameter to choose the MODE number read parameter setting mode. previously " 3. Turn the until " appears. appears. Pr. 30 must be set to "1". (For details, refer to steps 3 to 6 on page 19 .) ". SET 4. Press the SET to show " When adjusting Pr. 38 5. Turn the until the calibration parameter C4 "frequency setting voltage gain" appears. Analog voltage 6. Press the SET to show the SET value (%) across analog voltage value (%). terminals 2-5 * 7. Apply a 5V voltage. (Turn the external potentiometer connected to across terminals *The value is nearly 100 (%) in the maximum 2-5 to the maximum (any position).) position of the potentiometer. CAUTION After performing operation in step 7, do not touch the until completion of calibration. 2. Press the MODE 3 2 1 4 5 6 7 8 9 10 8. Press the SET to set the value. SET * Flicker ... Parameter setting complete!! (Adjustment complete) By turning the *The value is nearly 100 (%) in the maximum position of the potentiometer. , you can read another parameter. Press the SET to return to the " Press the SET " indication (step 4). twice to show the next parameter ( ). The frequency meter (indicator) connected to across terminals AM-5 does not indicate just 40Hz ... Why? The calibration parameter C1 "AM terminal calibration" value must be set. (Refer to page 28.) When write is performed, an error ( ) is displayed. The gain and bias frequency settings are too close. 27 ADJUSTMENT OF THE FREQUENCY SETTING POTENTIOMETER AND INDICATOR POINT The calibration parameter C4 is an extended function parameter. Pr. 30 must be set to "1". (2) Adjusting a deviation of the highest frequency from the Pr. 38 (Pr. 39) setting. (2)-1)Making adjustment with a voltage applied directly across terminals 2-5 (with a current flowing across terminals 4-5) 5 Adjustment (calibration) of the frequency meter (indicator) 5.2 Adjustment (calibration) of the frequency meter (indicator) Changing example Deflecting the meter (analog indicator) to full-scale (5V) at the preset frequency of 50Hz. (Refer to page 16 for frequency setting.) POINT • The calibration parameters "C1" can be made to be read by setting "1" (extended function parameter valid) in Pr. 30 "extended function display selection". • Set the value of the calibration parameter C1 "AM terminal calibration". Display Operation PU operation mode 1. Press the MODE to choose the parameter setting mode. to show " 2. Turn the setting. Pr. 30 must be set to "1". (For details, refer to steps 3 to 6 on page 19 .) 3. Press the SET to show " ". The parameter number read previously appears. MODE " SET until the calibration 4. Turn the parameter C1 "AM terminal calibration" appears. 5. Press the SET to enable setting. SET 6. If the inverter is at a stop, press the RUN to start the inverter. (A motor need not be connected.) to adjust the indicator 7. Turn the needle to the desired position. RUN PU RUN EXT Analog indicator 8. Press the SET . Setting is complete. SET Flicker...Parameter setting complete!! · By turning the , you can read another parameter. · Press the SET to return to the " · Press the SET twice to show the next parameter ( " indication (step 3). ). REMARKS • Depending on the set value, it may take some time for the needle to move. • If "1" is set in Pr. 30 "extended function display selection", the calibration parameter C1 "AM terminal calibration" can also be set in the external operation mode. POINT By setting the Pr. 54 "AM terminal function selection" value, preset Pr. 55 "frequency monitoring reference" or Pr. 56 "current monitoring reference" to the running frequency or current value at which the output signal is 5V. At 5V, the meter generally deflects to full-scale. 28 Basic function parameter list 6. FUNCTION LIST 6.1 Basic function parameter list Name 0 Torque boost 1 Maximum frequency Minimum frequency 2 3 Base frequency 4 Multi-speed setting (high speed) Multi-speed setting (middle speed) Multi-speed setting (low speed) 5 6 Indication Minimum Setting Increments Factory Setting 0 to 15% 0.1% 6%/5%/4% * 0 to 120Hz 0.1Hz 50Hz 0 to 120Hz 0.1Hz 0Hz 0 to 120Hz 0.1Hz 50Hz 0 to 120Hz 0.1Hz 50Hz 0 to 120Hz 0.1Hz 30Hz 0 to 120Hz 0.1Hz 10Hz Setting Range 7 Acceleration time 0 to 999s 0.1s 5s 8 Deceleration time 0 to 999s 0.1s 5s 9 Electronic thermal O/L relay Extended function display selection Operation mode selection 0 to 50A 0.1A Rated output current 0, 1 1 0 0 to 4, 7, 8 1 0 30 79 Customer Setting * The factory setting varies with the inverter capacity: 5% for FR-S540E-1.5K and 2.2K, 4% for FR-S540E-3.7K. Remarks • Setting "1" in Pr. 30 "extended function display selection" makes the extended function parameters valid. (Refer to page 19.) • The decimal places of a value of 100 or more (3 digits or more) cannot be set to be displayed. FUNCTION LIST Param eter 6 29 Explanation of the basic function parameters 6.2 Explanation of the basic function parameters For details, refer to the separately available instruction manual (detailed). Pr. 0 "torque boost" Pr. 1 "maximum frequency", Pr. 2 "minimum frequency" Allows the motor torque in the low speed range to be adjusted according to the load. Make adjustment when stall prevention is operated when starting. When a constant-torque motor is used, set the following value: 200V class 2.2K 3% (5%) Output frequency 0.2K 0.4K to 0.75K 1.5K 4% — 6% (5%) 4% 6% (6%) 400V class Clamp the upper and lower limits of the output frequency. 3.7K 3% (4%) — Values in parenthesis are factory-set Maximum frequency Pr.1 Minimum frequency Pr.2 Frequency setting Output voltage 100% 5V (10V) (20mA) etc. Pr.0 Setting range 0 Output frequency Base Pr.3 frequency Pr. 4 "multi-speed setting (high speed)" Pr. 5 "multi-speed setting (middle speed)" Pr. 6 "multi-speed setting (low speed)" Pr. 3 "base frequency" Set the base frequency (reference frequency at rated motor torque) within the range 0 to 120Hz according to the motor. You can select any speed (RH, RM, RL) by simply switching the external contact signal. Pr. 7 "acceleration time", Pr. 8 "deceleration time" RH RM RL As the acceleration time, set the time taken to reach the acceleration/deceleration reference frequency in Pr. 20 from 0Hz (factory set to 50Hz), and as the deceleration time, set the time taken to reach 0Hz from the Pr. 20 value (factory set to 50Hz). 0Hz Each speed (frequency) can be set to any value within the range 0 to 120Hz if the inverter is running. The extended functions enable setting of up to 15 speeds. Output frequency Pr.20 high-speed ON OFF OFF middle speed OFF ON OFF low speed OFF OFF ON Acceleration time Deceleration time Pr.7 Pr.8 30 Explanation of the basic function parameters Pr. 30 "extended function display selection" Pr. 9 "electronic thermal O/L relay" Set this parameter when showing/setting the extended function parameters. You can set a current value for protection of the motor from overheat. At the setting of 0A, motor protection does not function. (The output transistor protection of the inverter functions.) When connecting multiple motors to the inverter, provide external thermal relays to individual motors. For the 0.75K or less, this value is factoryset to 85% of the rated inverter current. Turn the RT signal on to select the second electronic thermal relay function. (Refer to page 41.) Setting 0 1 Definition Only basic functions are displayed. All parameters are displayed. Pr. 79 "operation mode selection" The inverter has two different operation modes: operation under control of external signals and operation from the PU (setting dial, Setting RUN ). You can use either or both operation modes. Definition 0 PU (setting dial, 1 2 PU (setting dial, RUN ) operation may be performed. Only external operation may be performed. RUN ) operation or external operation can be selected by the Running frequency Start signal • Setting made by the setting dial • Multi-speed selection External terminal (STF/STR) • 4 to 20mA (Made valid when the AU signal turns on) Running frequency 4 7 8 . Start signal External terminal signals (multi-speed, RUN 0 to 5VDC, etc.) PU operation interlock (Switching to the PU operation mode is enabled/disabled by turning the MRS signal ON/OFF) Operation mode external signal switching (disabled during operation) Turn the X16 signal ON/OFF to choose operation mode. 31 FUNCTION LIST 3 PU EXT 6 Extended function parameter list 6.3 Extended function parameter list Setting "1" in Pr. 30 "extended function display selection" makes the extended function parameters valid. (Refer to the separately available instruction manual (detailed).) Parameter Indication 10 11 12 13 14 15 16 Name Description For parameters 0 to 9, refer to the basic function parameters. (page 30) DC injection brake Set the timing of switching to DC injection operation frequency brake (0 to 120Hz), the time to apply DC DC injection brake injection brake (0 to 10s), and the braking operation time torque at DC injection brake start (0 to 15%). (Set Pr. 12 to 4% when a constantDC injection brake torque motor is used.) voltage Frequency which is output by the inverter first at a start and gives great influence to the starting torque. About 1 to 3Hz for vertical lift applications, or up to 5Hz to the Starting frequency maximum. For other than vertical lift applications, factory setting of about 0.5Hz is recommended. 0 to 60Hz Choose the output frequency and output voltage patterns according to the application (load characteristic). 0: For constant-torque loads (when relatively large torque is needed at low to high speeds) 1: For variable-torque loads (for Load pattern selection applications where torque is small at low speed, e.g. fans and pumps) 2: For vertical lifts (for elevators at reverse rotation boost of 0%) 3: For vertical lifts (for elevators at forward rotation boost of 0%) Speed command (0 to 120Hz) and Jog frequency acceleration/deceleration slope (0 to 999s) for jog (inching) operation When the FR-PU04 is connected, these Jog acceleration/ parameters can be read as the basic deceleration time parameters. 17 RUN key rotation direction selection 19 Base frequency voltage The RUN of the operation panel can be used to choose the direction of rotation for operation. 0: Forward rotation, 1: Reverse rotation Indicates the magnitude of the output voltage at the base frequency (Pr.3) 888: 95% of power supply voltage - - -: Same as power supply voltage 0 to 800V, 888, - - - 32 Factory Setting 3Hz 0.5s 6% 0.5Hz 0 5Hz 0.5s 0 888 Extended function parameter list 20 21 22 23 24 25 Name Description Indicates the frequency to be referenced for acceleration from or deceleration to 0Hz in the time set in Pr. 7 "acceleration time" or Pr. 8 "deceleration time". 1 to 120Hz Stall prevention is a function designed to suspend a frequency increase during Stall prevention acceleration, decrease frequency during function selection constant speed or suspend a frequency decrease during deceleration if the preset current (0 to 200%) is exceeded, in order to prevent an overcurrent alarm. Pr. 21 allows you to select whether to use stall prevention or not according to the Stall prevention acceleration/deceleration status. operation level Since the high response current limit value is 170%, torque will not be developed if Pr. 22 is set to more than 170%. In that case, set "1" in Pr. 21. Used to reduce the stall prevention level at or above the base frequency. Stall prevention Setting other than "- - -" specifies the operation level current level at 120Hz which is lower than compensation factor at the Pr. 22 value of the stall prevention level double speed at base frequency. 0 to 200%, - - Setting other than "- - -" specifies speeds 4 Multi-speed setting to 7. (speed4) By combining ON and OFF of the contact signals (RH, RM, RL signals), the running Multi-speed setting speed can be changed step-by-step. (speed 5) Acceleration/ deceleration base frequency Factory Setting 50Hz 0 150% --- ----- RH RM RL 26 Multi-speed setting (speed 6) 27 Multi-speed setting (speed 7) 28 29 Speed Speed Speed Speed 4 OFF ON ON 5 ON OFF ON 6 ON ON OFF 7 ON ON ON 0 to 120Hz, - - Stall prevention You can reduce the stall prevention level in the high frequency range. operation reduction 0 to 120Hz starting frequency Determines the frequency changing pattern for acceleration/deceleration. 0: Linear acceleration/deceleration Acceleration/ 1: S-pattern acceleration/deceleration A (e.g. machine tool spindle applications) deceleration pattern 2: S-pattern acceleration/deceleration B (for prevention of load shifting in conveyor and other applications.) For parameter 30, refer to the basic function parameters. (page 31) 33 ----- 50Hz 0 FUNCTION LIST Parameter Indication 6 Extended function parameter list Parameter Indication Name 31 Frequency jump 1A 32 Frequency jump 1B Description Factory Setting ----- Set the frequency range you want to evade during constant-speed operation to avoid resonance with a machine. 0 to 120Hz, - - - 33 Frequency jump 2A 34 Frequency jump 2B 35 Frequency jump 3A --- 36 Frequency jump 3B --- 37 38 39 40 41 42 You can convert the frequency monitor/set frequency of the operation panel into the load speed and display it. Setting 0 shows Speed display the output frequency, and setting 0.1 to 999 shows the load speed. (Set the speed for 60Hz operation.) 0, 0.1 to 999 You can set as desired the magnitude (slope) of the output frequency to the Frequency setting external frequency setting voltage signal voltage gain frequency (0 to 5V or 0 to 10V). 1 to 120Hz You can set as desired the magnitude (slope) of the output frequency to the Frequency setting external frequency setting current signal current gain frequency (4 to 20mA). 1 to 120Hz Set whether an earth fault is to be detected Start-time earth fault or not at a start. 0: Not detected detection selection 1: Detected You can adjust the ON range of the up-tofrequency signal (SU) to be output when the output frequency reaches the running frequency. You can use this function to ensure that the running frequency has been Up-to-frequency reached or use it as the operation start signal etc. for related equipment. Use Pr. 64 or Pr. 65 to assign the terminal used for SU signal output. 0 to 100% Set the reference value at which the signal (FU) is output when the output frequency rises to or above a certain value. This function can be used for electromagnetic Output frequency detection brake operation, open signal, etc. Use Pr. 64 or Pr. 65 to assign the terminal used for the FU signal. 0 to 120Hz 34 ----- 0 50Hz 50Hz 1 10% 6Hz Extended function parameter list Name 43 Output frequency detection for reverse operation 44 Second acceleration/ deceleration time 45 Second deceleration time 46 Second torque boost 47 Second V/F (base frequency) 48 Output current detection level 49 Output current detection signal delay time 50 Zero current detection level 51 Zero current detection period 52 Operation panel display data selection 53 Frequency setting operation selection 54 AM terminal function selection Description Set the reference value at which the signal (FU) is output when the output frequency rises to or above a certain value. This function is valid for reverse operation. 0 to 120Hz, - - Second function of the acceleration/ deceleration time set in Pr. 7, Pr. 8. 0 to 999s Second function for the deceleration time set in Pr. 8. 0 to 999s, - - Second function for the torque boost set in Pr. 0. 0 to 15%, - - Second function for the base frequency set in Pr. 3 0 to 120Hz, - - Set the level at which the output current detection signal (Y12) is output. 0 to 200% When the output current is at or above the output current detection level (Pr. 48) for longer than this period (Pr. 49), the output current detection signal (Y12) is output. 0 to 10s Set the level at which the zero current detection signal (Y13) is output. 0 to 200% When the output current is at or below the zero current detection level (Pr. 50) for longer than this period (Pr. 51), the zero current detection signal (Y13) is output. 0.05 to 1s You can choose the data displayed on the operation panel. 0: Output frequency 1: Output current 100: Set frequency during stop/output frequency during operation You can use the setting dial like a potentiometer to perform operation. 0: Setting dial frequency setting mode 1: Setting dial potentiometer mode You can choose the indicator connected to the AM terminal. 0: Output frequency monitor 1: Output current monitor 35 Factory Setting --- 5s --- --- --- 150% 0s 5% 0.5s FUNCTION LIST Parameter Indication 6 0 0 0 Extended function parameter list Parameter Indication Name 55 Frequency monitoring reference 56 Current monitoring reference 57 Restart coasting time 58 Restart cushion time 59 Remote setting function selection 60 RL terminal function selection 61 RM terminal function selection 62 RH terminal function selection 63 STR terminal function selection Description Set the reference value of frequency monitoring. 0 to 120Hz Set the reference value of current monitoring. 0 to 50A At power restoration after an instantaneous power failure, you can restart the inverter without motor being stopped (with the motor coasting). The inverter begins to restart after this period (Pr. 57) has elapsed after power restoration. When you set "- - -", a restart is not made. "0" setting generally does not pose a problem but you can adjust the time (0 to 5s, - - -) according to the magnitude of the load. When the restart coasting time (Pr. 57) has elapsed, the output voltage is risen gradually. Set this cushion time (Pr. 58) (0 to 60s). Operation may be performed generally at the factory setting, but you can adjust the time according to the magnitude of the load. Refer to additional parameter H6 for selection of speed search. (Refer to page 41.) You can set the remote setting function which is used when the operation panel is away from the enclosure, for example. 0: Without remote setting function 1: With remote setting function With frequency setting storage function 2: With remote setting function Without frequency setting storage function You can select the following input signals. 0: RL (multiple low-speed operation command) 1: RM (multiple middle-speed operation command) 2: RH (multiple high-speed operation command) 3: RT (second function selection) 4: AU (current input selection) 5: STOP (start self-holding selection) 6: MRS (output stop) 7: OH (external thermal relay input) 8: REX (15 multi-speed selection) 9: JOG (jog operation selection) 10: RES (reset) 14: X14 (PID control valid terminal) 16: X16 (PU operation/external operation switching) - - -: STR (reverse rotation start (may be assigned to only STR terminal)) 36 Factory Setting 50Hz Rated output current --- 1s 0 0 1 2 --- Extended function parameter list Name 64 RUN terminal function selection 65 A, B, C terminal function selection 66 Retry selection 67 Number of retries at alarm occurrence 68 Retry waiting time 69 Retry count display erase Description You can select the following input signals. 0: RUN (inverter running) 1: SU (up-to-frequency) 3: OL (overload warning) 4: FU (output frequency detection) 11: RY (operation ready) 12: Y12 (output current detection) 13: Y13 (zero current detection) 14: FDN (PID lower limit signal) 15: FUP (PID upper limit signal) 16: RL (PID forward/reverse rotation signal) 93: Y93 (current average value monitor signal (can be assigned to the RUN terminal only)) 95: Y95 (maintenance timer alarm) 98: LF (minor failure output) 99: ABC (alarm output) You can choose the retry alarm to be activated when the protective function is activated. 0: OC1 to 3, OV1 to 3, THM, THT, GF, OHT, OLT, PE, OPT 1: OC1 to 3, 2: OV1 to 3, 3: OC1 to 3, OV1 to 3 You can set the number of retries to be made when the protective function is activated. 0: No retry 1 to 10: Without alarm output during retry operation 101 to 110: With alarm output during retry operation You can set the waiting time from when the protective function is activated until a retry is made. 0.1 to 360s You can display the cumulative number of successful restarts made by retries when the protective function is activated. 0: Cumulative count erase 37 Factory Setting 0 99 0 0 1s FUNCTION LIST Parameter Indication 0 6 Extended function parameter list Parameter Indication 70 Name Soft-PWM setting You can select whether to exercise SoftPWM control and long wiring mode. When Soft-PWM is valid, you can change the metallic motor tone into an unoffending complex tone. Surge voltage is suppressed regardless of wiring length if the long wiring mode is set for the 400V class. Soft-PWM without with without with 0 1 10 11 71 Applied motor 72 PWM frequency selection 73 0-5V/0-10V selection 74 Input filter time constant Set the motor to be used. 0, 100: Thermal characteristic for Mitsubishi standard motor 1, 101: Thermal characteristic for Mitsubishi constant-torque motor When "100 or 101" is set, turning on the RT signal set the electronic thermal relay function to the thermal characteristic for the constant-torque motor. You can change the PWM carrier frequency. Increasing this value reduces the motor audible noise, but increases noise and leakage current. The setting is in [kHz]. 0: 0.7kHz, 15: 14.5kHz 0 to 15 (Remarks) Metallic sound may be generated from the motor at sudden deceleration but it is not a fault. You can set the input voltage specification of terminal "2". 0: For 0 to 5VDC input 1: For 0 to 10VDC input Valid for eliminating noise of the frequency setting circuit. A larger set value increases the time constant. 0 to 8 Reset selection/PU stop selection 0 1 0 1 STOP RESET PU Stop Key Input Invalid (Valid only in the PU operation Enabled only when the mode or combined 1 protective function is operation mode activated (Pr. 79=4)) 14 Normally enabled Enabled only when the Valid 15 protective function is activated 0 1 Long Wiring Mode without without with with You can choose the function of the on the operation panel. 75 Factory Setting Description Reset Input Normally enabled 38 14 Extended function parameter list 76 77 78 80 81 82 83 84 85 86 87 Name Description You can control the operation of the cooling fan built in the inverter. (Operates in poweron status.) 0: The fan normally operates at power on Cooling fan operation of the inverter. selection 1: The fan is normally on during inverter operation. The fan switches on/off according to the temperature during a stop of the inverter whose status is monitored. You can choose whether to enable or disable parameter write. 0: Write is enabled only during a stop in the Parameter write PU operation mode disable selection 1: Write disabled (except some parameters) 2: Write during operation enabled (external mode and during operation) You can prevent trouble during reverse operation due to false input of the start signal. Reverse rotation 0: Both forward rotation and reverse rotation prevention selection enabled 1: Reverse rotation disabled 2: Forward rotation disabled For parameter 79, refer to the basic function parameters. (page 31) Multi-speed setting Setting other than "- - -" specifies speeds 8 (speed 8) to 15. By combining ON and OFF of the contact Multi-speed setting signals (RH, RM, RL, REX signals), the (speed 9) running speed can be changed step-byMulti-speed setting step. (speed 10) Use Pr. 63 to assign the REX signal. Multi-speed setting RH RM RL REX (speed 11) Speed 8 OFF OFF OFF ON Multi-speed setting Speed 9 OFF OFF ON ON (speed 12) Speed 10 OFF ON OFF ON Multi-speed setting Speed 11 OFF ON ON ON (speed 13) Speed 12 ON OFF OFF ON Multi-speed setting Speed 13 ON OFF ON ON (speed 14) Multi-speed setting (speed 15) 88 PID action selection 89 PID proportional band 90 PID integral time 91 PID upper limit Speed 14 ON ON OFF ON Speed 15 ON ON ON ON 0 to 120Hz, - - Used to choose the operation of PID control. 20: PID reverse action, 21: PID forward action Used to set the proportional band for PID control. 0.1 to 999%, - - Used to set the integral time for PID control. 0.1 to 999s, - - Used to set the upper limit value for PID control. 0 to 100%, - - 39 Factory Setting 1 0 0 ----------------- 20 100% 1s --- FUNCTION LIST Parameter Indication 6 Extended function parameter list Parameter Indication Name 92 PID lower limit 93 PID action set point for PU operation 94 PID differential time 95 Rated motor slip 96 Slip compensation time constant 97 Constant output range slip compensation selection 98 Automatic torque boost selection (Motor capacity) 99 Motor primary resistance Description Used to set the lower limit value for PID control. 0 to 100%, - - Used to set the PID action set point for PU operation. 0 to 100% Used to set the differential time for PID control. 0.01 to 10s, - - Used to set the rated motor slip to make slip compensation. 0 to 50%, - - Used to set the response time of slip compensation. 0.01 to 10s Used to choose whether slip compensation is made or not in the constant output range. 0, - - You can set the motor capacity and exercise automatic torque boost control. When you set "- - -", V/F control is exercised. Set the motor capacity used. • The motor capacity should be equal to or one rank lower than the inverter capacity. • The number of motor poles should be 2, 4 or 6. (Only 4 poles for constant-torque motor) • Single-motor operation (one motor run by one inverter) should be performed. • Wiring length from inverter to motor should be within 30m. When using a constant-torque motor, set "1" in Pr. 71. <Example> For 1.5kW, set "1.5". 0.1 to 3.7kW, - - You can set the motor's primary resistance value. (Normally, this parameter need not be set.) 0 to 50Ω, - - - 40 Factory Setting --0% ----0.5s --- --- --- Extended function parameter list Maintenance parameters Parameter Indication H1 (503) H2 (504) H3 (555) H4 (556) H5 (557) Name Description Factory Setting Display the maintenance timer (cumulative energization time) in 1000h increments. 0 Parameter write is not enabled. 0 to 999 When the maintenance timer has elapsed Maintenance timer 36 the time set in H2, the Y95 signal is output. alarm output set time Assign the Y95 signal with Pr. 64 or Pr. 65. (36000h) 0 to 999, --The average value of the output current during constant speed operation and the maintenance timer value are output to the Current average time current average value monitor signal (Y93). 1s Y93 signal is output for 20s as 1 cycle in order of start bit for 1s(Hi), output current average value for 0.5 to 9s (Low), maintenance timer value for 2 to 9s (Hi), and end signal (Low). Assign the Y93 signal to the RUN terminal using Pr. 64. Data output mask time Set the time (0.1 to 1s) taken to calculate 0s average value of the output current during constant operation in H3. Set the time (0 to 20s) for not outputting the Y93 signal to invalidate retrieving of output current value in the transient state right after the speed is changed from Current average value acceleration/deceleration to constant monitor signal output 1A speed in H4. reference current Set the current value (0.1 to 999A) when outputting the average value of output current as a low pulse shape for 5s in H5. Maintenance timer Parameter Indication Name H6 (162) Automatic restart after instantaneous power failure selection H7 (559) Second electronic thermal relay function Description You can select whether to use system to detect the motor speed (speed search system) at the time of restart after instantaneous power failure or not 0: with speed search, 1: without speed search, 10: with speed search at starting Protect the second motor from overheat. Set the rated current value of the second motor. Made valid when the RT signal turns on. Refer to Pr. 9 for its function. 0 to 50A, --- 41 Factory Setting 1 FUNCTION LIST Additional parameters 6 --- Extended function parameter list Calibration parameter Parameter Indication C1 (901) C2 (902) C3 (902) C4 (903) C5 (904) C6 (904) C7 (905) C8 (269) Name Description You can calibrate the indicator connected AM terminal calibration to across terminals AM-5. — You can set as desired the magnitude (slope) of the output frequency to the Frequency setting external frequency setting voltage signal voltage bias frequency (0 to 5V or 0 to 10V). (Bias frequency) 0 to 60Hz Used to adjust the analog voltage value of Frequency setting the frequency set in calibration parameter voltage bias C2. (Bias %) 0 to 300% Used to adjust the analog voltage value of Frequency setting the frequency set in Pr. 38. (Gain %) voltage gain 0 to 300% You can set as desired the magnitude (slope) of the output frequency to the Frequency setting external frequency setting current signal current bias frequency (4 to 20mA). 0 to 60Hz Used to adjust the analog current value of Frequency setting the frequency set in calibration parameter current bias C5. (Bias %) 0 to 300% Used to adjust the analog current value of Frequency setting the frequency set in Pr. 39 (Gain %) current gain 0 to 300% Factory Setting — 0Hz 0%* 96%* 0Hz 20%* 100%* Parameter for manufacturer setting. Do not set. CLr Parameter clear ECL Alarm history clear 0: Not executed 1: Initialization of parameters other than calibration values (parameter clear) 10: Initialization of parameters including calibration values (all clear) 0: Not cleared 1: Alarm history clear *Settings may differ because of calibration parameters. 42 0 0 Extended function parameter list Communication parameters For details of the program, etc., refer to the instruction manual (detailed) separately available. POINT To make RS-485 communication between the inverter and personal computer, the operation mode must be set to the "computer link operation mode". Pr. 79 "operation mode selection" ≠ "1, 3, 4" and communication parameter n10 "link startup mode selection" = "1" (331) n2 (332) n3 (333) n4 (334) n5 (335) n6 (336) n7 (337) n8 (338) Name Description Set the station number for communication from the RS-485 connector. 0 to 31: Specify the station number of the inverter. 48: 4800bps Communication 96: 9600bps speed* 192: 19200bps 0: Stop bit length 1 bit/data length 8 1: Stop bit length 2 bits/data length 8 Stop bit length* 10: Stop bit length 1 bit/data length 7 11: Stop bit length 2 bits/data length 7 0: Absent Parity check 1: With odd parity check presence/absence* 2: With even parity check Set the permissible number of retries at Number of occurrence of a data receive error. When communication you set "- - -", the inverter will not come to an retries alarm stop if a communication error occurs. 0 to 10, - - Set the interval of communication check time. If a no-communication status persists for longer than the permissible time, the inverter will come to an alarm stop. Communication 0: No communication check time interval 0.1 to 999s - - -: Check suspended To make communication, set any value other than 0 in the communication parameter n6 "communication check time interval". Set the waiting time from when data is transmitted to the inverter until response is Waiting time setting* made. 0 to 150ms - - -: Set in communication data You can choose whether the operation command is given by the computer or the Operation command external terminal. source 0: Command source is computer 1: Command source is external terminal Communication station number* 43 Factory Setting 0 192 1 2 1 --- FUNCTION LIST Parameter Indication n1 6 --- 0 Extended function parameter list Parameter Indication n9 Name (339) Speed command source (340) Link startup mode selection n10 n11 CR/LF selection* (341) n12 E2PROM write selection (342) Description You can choose whether the speed command is given by the computer or the external terminal. 0: Command source is computer 1: Command source is external terminal You can choose the operation mode at power on or at power restoration after instantaneous power failure. Set "1" to select the computer link operation mode. 0: Mode set in Pr. 79 is established. 1: Started in computer link mode. 0: Without CR/LF 1: With CR, without LF 2: With CR/LF 0: Write to RAM and E2PROM 1: Write to RAM only (When a reset is performed, the parameter value will be the value of E2PROM.) Factory Setting 0 0 1 0 * Perform a reset after setting parameter. The set values are reflected after a reset. Parameters for the PU When the parameter unit (FR-PU04) is used, operation from the operation panel is not accepted.( STOP RESET is valid) Parameter Name Indication n13 PU display language (145) n14 (990) n15 Factory Setting selection 0: Japanese, 1: English, 2: German 3: French, 4: Spanish, 5: Italian 6: Swedish, 7: Finish 1 PU buzzer control 0: Without sound, 1: With sound 1 (991) PU contrast adjustment (992) PU main display screen data selection (993) Disconnected PU detection/PU setting lock n16 Outline n17 0 (Light) 63(Dark) 0: Selectable between output frequency and output current 100: Set frequency (during stop) Output frequency (during operation) 0: Without PU disconnection error/PU operation valid 1: Error at PU disconnection/PU operation valid 10: Without PU disconnection error/PU operation invalid 58 0 0 REMARKS • The parameter number in parentheses is the one for use with the parameter unit (FR-PU04). • Set "9999" when setting a value "- - -" using the parameter unit (FR-PU04). • Pr. stands for a parameter number. 44 About errors (definitions) 7. ERRORS AND PROTECTIVE FUNCTIONS 7.1 About errors (definitions) When an alarm occurs in the inverter, the protective function is activated to bring the inverter to an alarm stop and the PU display automatically changes to any of the following error (alarm) indications. For details, refer to the separately available instruction manual (detailed). (1) Major failures Function Name (OC1) Overcurrent shut-off during acceleration (OC2) Overcurrent shut-off during constant speed (OC3) Overcurrent shut-off during deceleration (OV1) (OV2) (OV3) (THM) (THT) (FIN) Regenerative overvoltage shut-off during acceleration Regenerative overvoltage shut-off during constant speed Regenerative overvoltage shut-off during deceleration or stop Definition The inverter output current rose to or above about 200% of the rated inverter current during acceleration. The inverter output current rose to or above about 200% of the rated inverter current during constant speed operation. The inverter output current rose to or above about 200% of the rated inverter current during deceleration. Excessive regenerative energy or surge voltage occurred during acceleration. Excessive regenerative energy or surge voltage occurred during constant speed. Excessive regenerative energy or surge voltage occurred during deceleration or stop. Overload or reduced cooling capability during lowMotor overload shut-off speed operation (Electronic thermal relay Protection against burnout due to motor function) (*1) temperature rise Inverter overload shut-off Current more than 150% of the rated output current (Electronic thermal relay flew and overcurrent shut-off did not occur. function) (*1) Output transistor protection from overheat Fin overheat Temperature rise of the heatsink. Start-time output side earth fault Earth fault occurred on the inverter's output side at (GF) overcurrent protection a start. (*2) *1. Resetting the inverter initializes the internal thermal integration data of the electronic thermal relay function. *2. Activated only when "1 (factory setting)" is set in Pr. 40 "start-time earth fault detection selection". 45 ERRORS AND PROTECTIVE FUNCTIONS Operation Panel Indication 7 About errors (definitions) Operation Panel Indication Function Name (OHT) External thermal relay (*3) (OLT) Stall prevention (overload) (OPT) Communication error (PE) Parameter storage device alarm (PUE) PU disconnected (RET) Retry count over (CPU) CPU error Definition External thermal relay provided for protection from overheat was actuated (contact open). Stall prevention was activated to drop the running frequency to 0. (OL appears while stall prevention is activated.) • Communication errors occurred consecutively more than the permissible number of retries when the RS-485 connector is used and communication parameter n5 ≠ "- - -". • RS-485 communication error occurred. • Communication has broken for a period set in communication parameter n6. Error occurred in the parameter stored. PU was disconnected when communication parameter n17 = "1". Operation could not be resumed properly within the preset number of retries. Arithmetic operation of the built-in CPU does not end within the predetermined time. *3. Activated only when any of Pr. 60 to Pr. 63 (input terminal function selection) is set to OH. (2) Minor failures Operation Panel Indication (FN) Function Name Fan trouble Definition The cooling fan built in the inverter failed (stopped). 46 About errors (definitions) (3) Warnings Operation Panel Indication Function Name (OL) Stall prevention (overcurrent) (*4) (oL) Stall prevention (overvoltage) (PS) PU stop (UV) Undervoltage Definition Current more than 150% of the rated inverter current flew in the motor and operation is being performed to prevent the inverter from resulting in overcurrent shut-off. Regenerative energy of the motor became excessive and operation is being performed to stop the frequency from decreasing to prevent overvoltage shut-off. Pr. 75 "reset selection/PU stop selection" had been set and a stop was made by pressing STOP the RESET of the operation panel or parameter unit (FR-PU04). Power supply voltage of the inverter dropped. During reset During inverter reset (RES signal is ON) (Err) *4. The stall prevention operation current may be set to any value. It is factory set to 150%. (4) Write errors (Er1) (Er2) (Er3) Function Name Definition • Write was performed with "1" set in Pr. 77 • Frequency jump setting range overlapped. Write disable error • Parameter write was performed though the operation panel does not have the write precedence. • Write was performed during operation. • An attempt was made to change the Pr. 79 Write-while-running setting to the operation mode where the error/mode designation operation command has been input. error • Write was performed in the external operation mode. Analog input bias and gain calibration values Calibration error are too close. Major failure:When the protective function is activated, the inverter output is shut-off and an alarm output is provided. Minor failure:When the protective function is activated, the output is not shut off. The minor failure signal can be output by making parameter setting. (Set "98" in Pr. 64 or Pr. 65 (output terminal function selection). Refer to page 37 .) ERRORS AND PROTECTIVE FUNCTIONS Operation Panel Indication 7 47 To know the operating status at the occurrence of alarm (only when FR-PU04 is used) 7.2 To know the operating status at the occurrence of alarm (only when FR-PU04 is used) When any alarm has occurred, the display automatically switches to the indication of the corresponding protective function (error). By pressing the MON at this point without resetting the inverter, the display shows the output frequency. In this way, it is possible to know the running frequency at the occurrence of the alarm. It is also possible to know the current in the same manner. After resetting, you can confirm the definitions in "Alarm History". (For details, refer to the instruction manual of the parameter unit (FR-PU04).) 7.3 Correspondence between digital and actual characters There are the following correspondences between the actual alphanumeric characters and the digital characters displayed on the operation panel: Actual Display Actual Display Actual 0 A M 1 B N 2 C O 3 D o 4 E P 5 F S 6 G T 7 H U 8 I V 9 J r L - Display 7.4 Resetting the inverter The inverter can be reset by performing any of the following operations. Note that the internal thermal integrated value of the electronic thermal relay function and the number of retries are cleared (erased) by resetting the inverter. Recover about 1s after reset is cancelled. (Err) flickers on the operation panel during reset. STOP Operation 1 ....... Using the operation panel, perform a reset with the RESET . (Enabled only when the inverter protective function is activated (major failure)) Operation 2 ........ Switch power off once, then switch it on again after the LED turns off. Operation 3 ....... Turn on the reset signal (RES). (Assign this signal to any of Pr. 60 to Pr. 63.) (Refer to page 36.) 48 Troubleshooting 7.5 Troubleshooting POINTS If the cause is still unknown after every check, it is recommended to initialize the parameters (return to factory setting) then re-set the required parameter values and check again. 7.5.1 Motor remains stopped 1) Check the main circuit Check that a proper power supply voltage is applied (operation panel display is provided). Check that the motor is connected properly. Check that the jumper across + - P1 is connected. Check that the start signal is input. Check that both the forward and reverse rotation start signals are not input simultaneously. Check that the frequency setting signal is not zero. Check that the AU signal is on when the frequency setting signal is 4 to 20mA. Check that the output stop signal (MRS) or reset signal (RES) is not on. (Assign signals MRS and RES using Pr. 60 to Pr. 63 (input terminal function selection).) Check that the sink or source jumper connector is fitted securely. 3) Check the parameter settings Check that the reverse rotation prevention (Pr. 78) is not selected. Check that the operation mode (Pr. 79) setting is correct. Check that the bias and gain (C2 to C7) settings are correct. Check that the starting frequency (Pr. 13) setting is not greater than the running frequency. Check that various operational functions (such as three-speed operation), especially the maximum frequency (Pr. 1), are not zero. 4) Check the load Check that the load is not too heavy. Check that the shaft is not locked. ERRORS AND PROTECTIVE FUNCTIONS 2) Check the input signals 7 5) Others Check that the operation panel display does not show an error (e.g. OC1). Check that the Pr. 15 "jog frequency" setting is not lower than the Pr. 13 "starting frequency" value. 49 Troubleshooting 7.5.2 Motor rotates in opposite direction Check that the phase sequence of output terminals U, V and W is correct. Check that the start signals (forward rotation, reverse rotation) are connected properly. Check the setting of Pr. 17 "RUN key rotation direction selection". 7.5.3 Speed greatly differs from the setting Check that the frequency setting signal is correct. (Measure the input signal level.) Check that the following parameter settings are correct (Pr. 1, Pr. 2, Pr. 19, Pr. 38, Pr. 39, Pr. 95, C2 to C7). Check that the input signal lines are not affected by external noise. (Use shielded cables) Check that the load is not too heavy. 7.5.4 Acceleration/deceleration is not smooth Check that the acceleration and deceleration time settings are not too short. Check that the load is not too heavy. Check that the torque boost setting is not too large to activate the stall prevention function. 7.5.5 Motor current is large Check that the load is not too heavy. Check that the torque boost setting is not too large. 7.5.6 Speed does not increase Check that the maximum frequency setting is correct. Check that the load is not too heavy. (In agitators, etc., load may become heavier in winter.) Check that the torque boost setting is not too large to activate the stall prevention function. 7.5.7 Speed varies during operation When slip compensation is selected, the output frequency varies with load fluctuation between 0 and 2Hz. This is a normal operation and is not a fault. 1) Inspection of load Check that the load is not varying. 2) Inspection of input signal Check that the frequency setting signal is not varying. Check that the frequency setting signal is not affected by noise. Check for a malfunction due to an undesirable current when the transistor output unit is connected. 3) Others Check that the wiring length is not too long. Check that GD2 load is not small. (at the motor GD2 or smaller) . . . . . . FR-S540E-1.5K to 3.7K If so, set the Pr. 72 "PWM frequency selection" to 6kHz or higher. (Check for noise or leakage current problem.) 50 Troubleshooting 7.5.8 Operation mode is not changed properly If the operation mode does not change correctly, check the following: 1. External input signal ............ Check that the STF or STR signal is off. When it is on, the operation mode cannot be changed. 2. Parameter setting ................ Check the Pr. 79 setting. When the Pr. 79 "operation mode selection" setting is "0", switching input power on places the inverter in the external operation mode. Press the PU EXT to switch to the PU operation mode. For other settings (1 to 8), the operation mode is limited accordingly. (For details of Pr. 79, refer to page 31.) 7.5.9 Operation panel display is not operating Make sure that terminals PC-SD are not shorted. 7.5.10 Parameter write cannot be performed Make sure that operation is not being performed (signal STF or STR is not ON). Check that the SET ( WRITE ) was pressed. Make sure that you are not attempting to set the parameter outside the setting range. Make sure that you are not attempting to set the parameter in the external operation mode. Check Pr. 77 "parameter write disable selection". 7.5.11 Motor produces annoying sound Check the Pr. 70 "Soft-PWM setting" and Pr. 72 "PWM frequency selection" settings. Make sure that the deceleration time is not too short. 51 ERRORS AND PROTECTIVE FUNCTIONS Make sure that the connector is fitted securely across terminals + - P1. 7 Precautions for maintenance and inspection 7.6 Precautions for maintenance and inspection The inverter is a static unit mainly consisting of semiconductor devices. Daily inspection must be performed to prevent any fault from occurring due to the adverse effects of the operating environment, such as temperature, humidity, dust, dirt and vibration, changes in the parts with time, service life, and other factors. 7.6.1 Precautions for maintenance and inspection For some short time after the power is switched off, a high voltage remains in the smoothing capacitor. When accessing the inverter for inspection, wait for at least 10 minutes after the power supply has been switched off, and then make sure that the voltage across the main circuit terminals + - - of the inverter is not more than 30VDC using a tester, etc. 7.6.2 Inspection item (1) Daily inspection •Basically, check for the following faults during operation. 1)Motor operation fault 2)Improper installation environment 3)Cooling system fault 4)Abnormal vibration, abnormal noise 5)Abnormal overheat, discoloration • During operation, check the inverter input voltages using a tester. (2) Cleaning Always run the inverter in a clean status. When cleaning the inverter, gently wipe dirty areas with a soft cloth immersed in neutral detergent or ethanol. CAUTION Do not use solvent, such as acetone, benzene, toluene and alcohol, as they will cause the inverter surface paint to peel off. 7.6.3 Periodic inspection Check the areas inaccessible during operation and requiring periodic inspection. Consult us for periodic inspection. 1)Cooling system fault. ........................... Clean the air filter, etc. 2)Tightening check and retightening ........ The screws and bolts may become loose due to vibration, temperature changes, etc. Check and tighten them. Tighten them according to the specified tightening torque. 3)Check the conductors and insulating materials for corrosion and damage. 4)Measure insulation resistance. 5)Check and replace the cooling fan, smoothing capacitor and relay. 52 Precautions for maintenance and inspection 7.6.4 Insulation resistance test using megger 1) Before performing the insulation resistance test on the external circuit, disconnect the cables from all terminals of the inverter so that the test voltage is not applied to the inverter. 2) For the continuity test of the control circuit, use a tester (high resistance range) and do not use the megger or buzzer. 3) For the inverter, conduct the insulation resistance test on the main circuit only as shown below and do not perform the test on the control circuit. (use the 500VDC megger) L1 L2 L3 Power supply Inverter U V W Motor IM 500VDC megger Earth terminal 7.6.5 Pressure test Interval General Check ambient Surrounding temperature, environment humidity, dust, dirt, etc. Check for unusual Overall unit vibration and noise. Power supply voltage Check that the main circuit voltages are normal. Periodic* Daily Inspection Inspection Item Item Method Criterion Measure 5cm Ambient away from the temperature: -10°C to +50°C, inverter. non-freezing. Ambient humidity: 90% or less, noncondensing. No fault Visual and auditory checks. Within Measure permissible AC voltages across inverter (DC) voltage terminal block fluctuation (Refer to page L1, L2, L3 63.) phases. 53 Instrument Thermometer, hygrometer, recorder Customer's check Daily and periodic inspection 1 year 2 year Area of inspection 7.6.6 ERRORS AND PROTECTIVE FUNCTIONS Do not conduct a pressure test. Deterioration may occur. 7 Tester, digital multimeter General (1) Check with megger (across main circuit terminals and earth terminal). (2) Check for General loose screws and bolts (3) Check for overheat traces on the parts (4) Cleaning (1) Check conductors for distortion. Conductors, cable (2) Check cable sheaths for breakage Terminal Check for block damage. Main circuit Inverter module, Converter module Smoothing capacitor Relay Check resistance across terminals. (1) Check for liquid leakage. (2) Check for safety valve projection and bulge. (3) Measure electrostatic capacity. (1) Check for chatter during operation. (2) Check for rough surface on contacts. Periodic* Daily Inspection Inspection Item Item Method Criterion Instrument (1) Disconnect (1)5MΩ or more 500VDC class all cables (2), (3) No fault megger from the inverter and measure across terminals L1, L2, L3, U, V, W and earth terminal with megger., (2) Retighten (3) Visual check (1), (2) Visual check (1), (2) No fault Visual check No fault Disconnect all cables from the inverter and measure across terminals L1, L2, L3↔+, and U, V, W↔+, - with a meter range of 100Ω. (1), (2) Visual check (3) Measure with capacity meter (1) Auditory check (2) Visual check 54 Refer to page 56. Analog tester (1), (2) No fault. Capacity (3) 85% or more meter of the rated capacity (1) No fault (2) No fault Customer's check Interval 1 year 2 year Area of inspection Precautions for maintenance and inspection Operation check Cooling fan Indication Meter Motor General Insulation resistance Daily Periodic* (1) Check balance of output voltages across phases with the inverter operated alone. (2) Perform sequence protective operation test to ensure no fault in protective and display circuits. (1) Check for unusual vibration and noise. (2) Check for loose screws and bolts (1) Check for LED lamp blown. (2) Cleaning Check that reading is normal. (1) Check for unusual vibration and noise. (2) Check for unusual odor. (1) Check with megger (across terminals and earth terminal). 1 year 2 year Inspection Inspection Item Item Method (1) (1) Measure voltages across the inverter output terminals U-V-W. (2) Simulatively short or (2) open the protective circuit output terminals of the inverter. Criterion Phase-tophase voltage balance Within 4V for the 200V and within 8V for the 400V class Fault must occur because of sequence. Instrument Customer's check Interval Digital multimeter, rectifier type voltmeter (1) Turn by hand No unusual with power vibration and noise. off. (2) Visual check (1) Check that the (1) Lamps lamps are lit. indicate indicator lamps on panel. (2) Clean with rag. Voltmeter, Must satisfy Check the ammeter,etc. readings of the specified and management meters on the values. panel. (1), (2) No fault (1) Auditory, sensory, visual checks. (2) Check for unusual odor due to overheat, damage, etc. (1) Disconnect (1) 5MΩ or more 500V megger cables from U, V, W (including motor cables) Consult us for periodic inspection. 55 ERRORS AND PROTECTIVE FUNCTIONS Display Cooling system Control circuit Protective circuit Area of inspection Precautions for maintenance and inspection 7 Precautions for maintenance and inspection Checking the inverter and converter module <Preparation> (1) Disconnect the external power supply cables (L1, L2, L3) and motor cables (U, V, W). (2) Prepare a tester. (Use 100Ω range). <Checking method> Change the polarity of the tester alternately at the inverter terminals L1, L2, L3, U, V, W, P and N, and check for continuity. CAUTION •Before measurement, check that the smoothing capacitor is discharged. •At the time of discontinuity, the measured value is almost ∞. When there is an instantaneous continuity, due to the smoothing capacitor, the tester may not indicate ∞. At the time of continuity, the measured value is several to several ten's-of ohms depending on the module type, circuit tester type, etc. If all measured values are almost the same, the modules are without fault. Module device numbers and terminals to be checked D1 Module Converter Tester Polarity D2 D3 Module Inverter TR1 TR3 TR5 L1 + L2 + L3 + U + V + W + + L1 + L2 + L3 + U + V + W Tester Polarity Process value Discontinuity Continuity Discontinuity Continuity Discontinuity Continuity Discontinuity Continuity Discontinuity Continuity Discontinuity Continuity − L1 − L2 − L3 − U − V − W L1 − L2 − L3 − U − V − W − D4 D5 D6 TR4 TR6 TR2 Process value Continuity Discontinuity Continuity Discontinuity Continuity Discontinuity Continuity Discontinuity Continuity Discontinuity Continuity Discontinuity (Assumes the use of an analog meter.) Converter module + Inverter module TR1 D1 D2 TR3 TR5 D3 L1 U C L2 V L3 W D4 D5 D6 TR4 TR6 − REMARKS The FR-S520SE-0.2K to 1.5K-EC do not have L3, D3 and D6. 56 TR2 Precautions for maintenance and inspection 7.6.7 Replacement of parts The inverter consists of many electronic parts such as semiconductor devices. The following parts may deteriorate with age because of their structures or physical characteristics, leading to reduced performance or fault of the inverter. For preventive maintenance, the parts must be replaced periodically. Part Name Cooling fan Main circuit smoothing capacitor On-board smoothing capacitor Relays Standard Replacement Interval Description 2 to 3 years Replace (as required) 10 years * Replace (as required) 10 years * Replace the board (as required) — Replace as required * The design life of electrolytic capacitor is about ten years (36000h) if used for 10 hours a day and 365 days a year in the average yearly ambient temperature of 40°C. ERRORS AND PROTECTIVE FUNCTIONS CAUTION For parts replacement, consult the nearest Mitsubishi FA Center. 7 57 Precautions for maintenance and inspection (1) Cooling fan The cooling fan is used to cool heat-generating parts such as the main circuit semiconductors. The life of the cooling fan bearing is usually 10,000 to 35,000 hours. Hence, the cooling fan must be replaced every 2 to 3 years if the inverter is run continuously. When unusual noise and/or vibration is noticed during inspection, the cooling fan must be replaced immediately. Inverter Type Fan Type FR-S520SE-1.5K-EC FR-S540E-1.5K, 2.2K, 3.7K-EC MMF-06D24DS BKO-C2461H07 MMF-06D24ES-FC4 BKO-CA1027H09 Removal 1) Remove the front cover and wiring cover. (Refer to page 1.) 2) Unplug the fan connectors. The cooling fan is connected to the cooling fan connector beside the main circuit terminal block of the inverter. Unplug the connector and separate the inverter from the cooling fan. 3) Remove the cooling fan cover. Disengage the fixing hooks pointed by arrows to remove the cooling fan cover. 4) Remove the cooling fan and cooling fan cover. The cooling fan is secured by AIR FLOW the fixing hooks. Disengage the fixing hooks to remove the cooling fan and cooling fan cover. Reinstallation 1) After confirming the orientation of the fan, reinstall the fan so that the arrow on the left of "AIR FLOW" faces up. CAUTION Installing the fan in the opposite air flow direction can cause the inverter life to be shorter. 2) Reinstall the fan cover to the inverter. Run the cable through the wiring groove to prevent it from being caught between the chassis and cover. 3) Reconnect the cable to the connector. (Refer to "Removal" on the previous page for the position of the connector.) 4) Reinstall the wiring cover. 58 Precautions for maintenance and inspection (2) Smoothing capacitors A large-capacity aluminum electrolytic capacitor is used for smoothing in the main circuit DC section, and an aluminum electrolytic capacitor is used for stabilizing the control power in the control circuit. Their characteristics are deteriorated by the adverse effects of ripple currents, etc. The replacement intervals greatly vary with the ambient temperature and operating conditions. When the inverter is operated in airconditioned, normal environment conditions, replace the capacitors about every 10 years. When a certain period of time has elapsed, the capacitors will deteriorate more rapidly. Check the capacitors at least every year (less than six months if the life will be expired soon). The appearance criteria for inspection are as follows: 1) Case: Check the side and bottom faces for expansion 2) Sealing plate: Check for remarkable warp and extreme crack. 3) Check for external crack, discoloration, fluid leakage, etc. Judge that the capacitor has reached its life when the measured capacitance of the capacitor reduced below 85% of the rating. (3) Relays ERRORS AND PROTECTIVE FUNCTIONS To prevent a contact fault, etc., relays must be replaced according to the cumulative number of switching times (switching life). 7 59 Precautions for maintenance and inspection 7.6.8 Measurement of main circuit voltages, currents and powers • Measurement of voltages and currents Since the voltages and currents on the inverter power supply and output sides include harmonics, measurement data depends on the instruments used and circuits measured. When instruments for commercial frequency are used for measurement, measure the following circuits with the instruments given on the next page. Three-phase 400V power input Input voltage Output voltage Input current Output current Single-phase 200V power input Inverter Ar Three-phase power supply W11 U L1 Au Vr As W12 V L2 Av Vs At W21 Vu To motor Vv W13 L3 W Vt Aw W22 Vw + The FR-S520SE-0.2K to 1.5K do not have As, At, Vt, Vs, W12 and W13. - :Electrodynamometer type V + :Moving-iron type - Instrument types :Moving-coil type :Rectifier type Examples of Measuring Points and Instruments CAUTION Use an FFT to measure the output voltages accurately. A tester or general measuring instrument cannot measure accurately. 60 Precautions for maintenance and inspection Measuring Points and Instruments Item Power supply voltage V1 Measuring Point Measuring Instrument Across L1-L2, L2-L3, L3-L1 Moving-iron type AC voltmeter Remarks (Reference Measurement Value) Commercial power supply Within permissible AC voltage fluctuation (Refer to page 63.) Power supply side L1, L2, and L3 Moving-iron current line currents type AC ammeter I1 At L1, L2 and Power supply side L3, and across Electrodynamic type P1 = W11 + W12 + W13 power L1-L2, L2-L3 single-phase wattmeter (3-wattmeter method) P1 and L3-L1 Calculate after measuring power supply voltage, power supply side current and power supply side power. Power supply side [For single-phase power supply] [Three phase power supply] power factor P1 P1 Pf1 Pf1= Across U-V, V-W and W-U Pf1= 100% Rectifier type AC voltmeter (Caution 1) (Moving-iron type cannot measure) V1 I1 100% Difference between the phases is within ±1% of the maximum output voltage. Current should be equal to or less than rated inverter current. U, V and W Difference between the phases is line currents 10% or lower of the rated inverter current. P2 = W21 + W22 Electrodynamic type Output side power U, V, W and 2-wattmeter method P2 U-V, V-W single-phase wattmeter (or 3-wattmeter method) Output side power Calculate in similar manner to power supply side power factor. factor P2 Pf2= 100% Pf2 3V2 I2 Converter output Moving-iron type AC ammeter (Caution 2) Across + - − Across 2 (positive)-5 Across 4 (positive)-5 Frequency setting Across power supply 10(positive)-5 Frequency setting signal Frequency meter signal Across AM(positive)-5 Moving-coil type (such as tester) Inverter LED display is lit 1.35 × V1 0 to 5VDC/0 to 10VDC Moving-coil type (Tester and such may 4 to 20mADC be used) (Internal resistance: 5VDC 50kΩ or larger) Approx. 5VDC at maximum frequency (without frequency meter) "5" is common Output side current I2 ERRORS AND PROTECTIVE FUNCTIONS Output side voltage V2 3V1 I1 7 61 Precautions for maintenance and inspection Start signal Select signal Alarm signal Measuring Point Across STF, STR, RH, RM, RL-PC(positive) Across A-C Across B-C Measuring Instrument Remarks (Reference Measurement Value) Moving-coil type (Tester and such may When open be used) 20 to 30VDC (Internal resistance: ON voltage: 1V or less 50kΩ or larger) Moving-coil type (such as tester) "PC" is common Item Continuity check <Normal> <Abnormal> Across A-C: Discontinuity Continuity Across B-C: Continuity Discontinuity CAUTION 1. Use an FFT to measure the output voltage accurately. An FA tester or general measuring instrument cannot measure accurately. 2. When the carrier frequency exceeds 5kHz, do not use this instrument since using it may increase eddy-current losses produced in metal parts inside the instrument, leading to burnout. In this case, use the approximately effective value type instrument. 62 Ratings 8. SPECIFICATIONS 8.1 Ratings (1) Three-phase 400V power supply Type FR-S540E- K-EC Power supply Output Applied motor capacity (kW) (*1) Rated capacity (kVA) (*2) Rated current (A) Overload current rating (*3) Voltage (*4) Rated input AC voltage/frequency Permissible AC voltage fluctuation Permissible frequency fluctuation Power supply system capacity (kVA) (*5) Protective structure (JEM1030) Cooling system Approximate mass (kg) 0.4 0.75 1.5 2.2 3.7 0.4 0.75 1.5 2.2 3.7 0.9 1.6 2.7 3.7 5.9 1.1 2.1 3.5 4.8 7.7 150% 60s, 200% 0.5s (Inverse time characteristics) Three phase, 380V to 480V 50Hz/60Hz Three phase, 380V to 480V 50Hz/60Hz 325 to 528V 50Hz/60Hz ±5% 1.5 2.5 4.5 5.5 9.5 Enclosed type (IP20) Self-cooling Forced air cooling 1.5 1.5 1.5 1.6 1.7 SPECIFICATIONS *1. The applied motor capacity indicated is the maximum capacity applicable for use of the Mitsubishi 4-pole standard motor. *2. The rated output capacity indicated assumes that the output voltage is 440V. *3. The % value of the overload current rating indicates the ratio of the overload current to the inverter's rated output current. For repeated duty, allow time for the inverter and motor to return to or below the temperatures under 100% load. *4. The maximum output voltage does not exceed the power supply voltage. You can set the maximum output voltage to any value below the power supply voltage. However, the pulse voltage value of the inverter output side voltage remains unchanged at about 2 that of the power supply. *5. The power supply capacity varies with the value of the power supply side inverter impedance (including those of the input reactor and cables). 8 63 Ratings (2) Single-phase 200V power supply Type FR-S520SE- K-EC Power supply Output Applicable motor capacity (kW) (*1) Rated capacity (kVA) (*2) Rated current (A) Overload current rating (*3) Voltage (*4) Rated input AC voltage/frequency Permissible AC voltage fluctuation Permissible frequency fluctuation Power supply system capacity (kVA) (*5) Protective structure (JEM1030) 0.2 0.9 0.75 1.5 1.5 2.5 4.4 Enclosed type (IP20) Cooling system Approximate mass (kg) 0.4 0.2 0.4 0.75 1.5 0.5 1.0 1.6 2.8 1.4 2.5 4.1 7.0 150% 60s, 200% 0.5s (Inverse time characteristics) Three phase, 200V to 240V 50Hz/60Hz Single-phase, 200V to 240V 50Hz/60Hz 170 to 264V 50Hz/60Hz ±5% Self-cooling 0.6 0.8 1.0 Forced air cooling 1.5 *1. The applied motor capacity indicated is the maximum capacity applicable when a Mitsubishi 4-pole standard motor is used. *2. The rated output capacity indicated assumes that the output voltage is 230V. *3. The % value of the overload current rating indicates the ratio of the overload current to the inverter's rated output current. For repeated duty, allow time for the inverter to return to or below the temperatures under 100% load. *4. The maximum output voltage does not exceed the power supply voltage. The maximum output voltage may be set as desired below the power supply voltage. However, the PWM pulse voltage value of the inverter output side voltage remains unchanged at about 2 that of the power supply. *5. The power supply capacity changes with the values of the power supply side inverter impedances (including those of the input reactor and cables). 64 Common specifications 8.2 Common specifications Selectable between Soft-PWM control and high carrier frequency PWM control, V/F control or automatic torque boost control are selectable. 0.5 to 120Hz (starting frequency variable between 0 and Output frequency range 60Hz) 5VDC input: 1/500 of max. set frequency, 10VDC, Frequency setting resolution 4 to 20mADC input: 1/1000 of max. set frequency Digital input: 0.1Hz (less than 100Hz), 1Hz (100Hz or higher) Analog input: Within ±1% of max. output frequency (25°C±10°C) Frequency accuracy Digital input: Within ±0.5% of set output frequency (when set by the setting dial) Starting torque 150% (at 5Hz) during automatic torque boost control 0, 0.1 to 999s (acceleration and deceleration can be set Acceleration/deceleration individually), linear or S-pattern acceleration/deceleration time setting mode can be selected. 0.2K ... 150%, 0.4K, 0.75K ... 100%, 1.5K ... 50%, Regeneration 2.2K, 3.7K ... 20% Braking torque (*2) DC injection Operation frequency (0 to 120Hz), operation time (0 to 10s), brake operation voltage (0 to 15%) Frequency Analog input 0 to 5VDC, 0 to 10VDC, 4 to 20mA setting Digital input Entered from operation panel signal Forward and reverse rotation, start signal Start signal STF, STR automatic self-holding input (3-wire input) can be selected. Used to reset alarm output provided when Alarm reset protective function is activated. Up to 15 speeds can be selected. (Each speed can be set between 0 and 120Hz, running speed Multi-speed selection can be changed during operation from the operation panel.) Used to select second functions (acceleration Use Second function selection time, deceleration time, torque boost, base Pr. 60 to frequency, electronic thermal relay function). Pr. 63 for Instantaneous shut-off of inverter output Output stop selection (frequency, voltage) Used to select frequency setting signal 4 to 20 Current input selection mA (terminal 4). External thermal relay Thermal relay contact input for use when the input inverter is stopped by the external thermal relay. Jog signal Jog operation mode selection PID control valid Selection for exercising PID control PU operation /external Used to switch between PU operation and operation switchover external operation from outside the inverter. 65 SPECIFICATIONS Input signals Control specifications Control system 8 Common specifications Output signals Control specifications Operational functions Operating Status For meter Environment Protective/warning function Ambient temperature Ambient humidity Storage temperature (*6) Maximum and minimum frequency settings, frequency jump operation, external thermal relay input selection, automatic restart after instantaneous power failure, forward/reverse rotation prevention, slip compensation, operation mode selection, PID control, computer link operation (RS-485). 1 open collector signal can be selected from among inverter running, up-to-frequency, frequency detection, overload warning, zero Use current detection, output current detection, PID Pr. 64 and upper limit, PID lower limit, PID forward/reverse Pr. 65 for rotation, operation ready, current average value selection monitor signal, maintenance timer alarm, minor failure and alarm. 1 contact output (1 contact, 230V 0.3AAC, 30V 0.3ADC) signal can be selected. 1 signal can be selected from between output frequency and motor current. Analog output (0 to 5VDC) Overcurrent shut-off (during acceleration, deceleration, constant speed), regenerative overvoltage shut-off (during acceleration, deceleration, constant speed), overload shutoff (electronic thermal relay function), heatsink overheat, fan failure (*3), stall prevention, start-time output side earth fault protection (*4), external thermal relay (*5), disconnected PU, retry count over, communication error, CPU error, undervoltage (*1) -10°C to +50°C (non-freezing) 90%RH or less (non-condensing) -20°C to +65°C Indoors (without corrosive gas, flammable gas, oil mist, dust and dirt etc.) Maximum 1000m above sea level for standard operation. After that derate by 3% for every extra 500m up to 2500m Altitude, vibration (91%). 5.9m/s2 or less (conforms to JIS C 60068-2-6) *1. When undervoltage or instantaneous power failure occurs, no alarm output is provided but the output is shut off. After power restoration, the inverter may be run as it is. Depending on the running status (e.g. load magnitude), however, overcurrent, regenerative overvoltage or other protection may be activated at power restoration. (in the external operation mode) *2. The braking torque indicated is a short-duration average torque (which varies with motor loss) when the motor alone is decelerated from 60Hz in the shortest time and is not a continuous regenerative torque. When the motor is decelerated from the frequency higher than the base frequency, the average deceleration torque will reduce. *3. Compatible with only the product having the built-in cooling fan. *4. Activated only when "1 (factory setting)" is set in Pr. 40 "start-time earth fault detection selection". *5. Activated only when external thermal relay input (OH) is selected in any of Pr. 60 to Pr. 63 (input terminal function selection). *6. Temperature applicable for a short period such as transportation. Atmosphere 66 OUTLINE DRAWINGS 9. OUTLINE DRAWINGS φ5 hole + 118 128 - 5 •FR-S520SE-0.2K, 0.4K, 0.75K-EC 5 56 68 4 6 18.5 D1 D2 D •Single-phase 200V power supply Capacity 0.2K 0.4K 0.75K D 80.5 142.5 162.5 D1 10 42 62 D2 52 82 82 (Unit: mm) OUTLINE DRAWINGS 6 5 Rating plate 9 67 OUTLINE DRAWINGS •FR-S540E-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-EC •FR-S520SE-1.5K-EC 5 φ5 hole + 118 128 - Rating plate Cooling fan×1 5 6 D3 6 W1 W 18.5 D2 D1 D •Three-phase 400V power supply Capacity 0.4K,0.75K 1.5K 2.2K 3.7K W 108 108 108 108 W1 96 96 96 96 D 129.5 135.5 155.5 165.5 D1 59 65 65 65 D2 52 52 72 82 D3 5 8 8 8 •Single-phase 200V power supply Capacity 1.5K W 108 W1 96 D 155.5 D1 65 D2 72 D3 8 (Unit: mm) REMARKS • The FR-S540E-0.4K, 0.75K-EC do not have a cooling fan. 68 OUTLINE DRAWINGS •Parameter unit (FR-PU04) <Outline drawing> <Panel cut dimension drawing> 16.5 24 23.75 1.5 5- 4 hole 1.5 13 14.5 20 11.75 80 125 21.5 13 17 48 81.5 10.5 18.5 15 72 1.25 5-M3 hole Effective depth 4.5 40 40 (Unit:mm) OUTLINE DRAWINGS Choose the mounting screws whose length will not exceed the effective depth of the mounting threads. 9 69 Appendix 1 Instructions for compliance with the European Directive (The products conforming to the Low Voltage Directive carry the CE mark.) (1) EMC Directive 1)Our view of transistorized inverters for the EMC Directive A transistorized inverter is a component designed for installation in an enclosure and for use with the other equipment to control the equipment/device. Therefore, we understand that the EMC Directive does not apply directly to transistorized inverters. For this reason, we do not place the CE mark on the transistorized inverters. (The CE mark is placed on inverters in accordance with the Low Voltage Directive.) The European power drive manufacturers' organization (CEMEP) also holds this point of view. 2)Compliance We understand that the transistorized inverters are not covered directly by the EMC Directive. However, the EMC Directive applies to machines/equipment into which transistorized inverters have been incorporated, and these machines and equipment must carry the CE marks. Hence, we prepared the European Standardcompliant noise filters and the technical information "EMC Installation Guidelines" (information number BCN-A21041-202) so that machines and equipment incorporating transistorized inverters may conform to the EMC Directive more easily. 3)Outline of installation method Install an inverter using the following methods: * Use the inverter with an European Standard-compliant noise filter. * For wiring between the inverter and motor, use shielded cables or run them in a metal piping and earth the cables on the inverter and motor sides with the shortest possible distance. * Insert a line noise filter and ferrite core into the power and control lines as required. Full information including the European Standard-compliant noise filter specifications are written in the technical information "EMC Installation Guidelines" (BCN-A21041-202). Please contact your sales representative. 70 (2) Low Voltage Directive 1) Our view of transistorized inverters for the Low Voltage Directive Transistorized inverters are covered by the Low Voltage Directive (Standard to conform to: EN50178). 2) Compliance We have self-confirmed our inverters as products compliant to the Low Voltage Directive and place the CE mark on the inverters. 3) Outline of instructions * For the 400V class inverter, the rated input voltage range is three phase 380V to 415V 50Hz/60Hz. * Do not use an earth leakage circuit breaker as an electric shock protector without connecting the equipment to the earth. Connect the equipment to the earth securely. * Wire the earth terminal independently. (Do not connect two or more cables to one terminal.) * Use the cable sizes on page 8 under the following conditions. ·Ambient temperature: 40°C maximum * * * * * * * ·Wire installation: On wall without ducts or conduits If conditions are different from above, select appropriate wire according to EN60204 ANNEX C TABLE 5. Use the no-fuse breaker and magnetic contactor which conform to the EN or IEC Standard. Use the breaker of type B (breaker which can detect both AC and DC). If not, provide double or enhanced insulation between the inverter and other equipment, or put a transformer between the main power supply and inverter. Use the inverter under the conditions of overvoltage category II and contamination level 2 or higher specified in IEC664. On the input and output of the inverter, use cables of the type and size set forth in EN60204 Appendix C. The operating capacity of the relay outputs (terminal symbols A, B, C) should be 30VDC, 0.3A. Control circuit terminals on page 9 are safely isolated from the main circuit. Environment During transportation Ambient Temperature -10°C to +50°C -20°C to +65°C -20°C to +65°C Ambient Humidity 90% RH or less 90% RH or less 90% RH or less Maximum Altitude 1,000m 1,000m 10,000m Details are given in the technical information "Low Voltage Directive Conformance Guide" (BCN-A21041-203). Please contact your sales representative. During operation 71 In storage Appendix 2 Instructions for UL and cUL (Standard to comply with: UL 508C, CSA C22.2 No.14) 1. Installation The S500E is UL-listed as a product for use in an enclosure. Design the enclosure so that the ambient temperature, humidity and ambience of the inverter will satisfy the above specifications. (Refer to page 66) Branch circuit protection For installation in the United States, branch circuit protection must be provided in accordance with the National Electrical Code and any applicable local codes. For installation in Canada, branch circuit protection must be provided in accordance with the Canada Electrical Code and any applicable provincial codes. 2. Wiring of the power supply and motor For wiring the input (L1, L2, L3) and output (U, V, W) terminals of the inverter, use the UL-listed copper wires (rated at 75°C) and round crimping terminals. Crimp the crimping terminals with the crimping tool recommended by the terminal maker. 3. Short circuit ratings Suitable For Use in A Circuit Capable Of Delivering Not More Than 5kA rms Symmetrical Amperes. 72 4. Motor overload protection These inverters provide solid state motor overload protection. Set Pr. 9 using the following instructions, (Pr. 9 "electronic thermal O/L relay"). <Setting> • Set the rated current [A] of the motor in Pr. 9. • Setting "0" in Pr. 9 disables electronic thermal relay function (motor protective function). (The protective function of the inverter is activated.) • When using a Mitsubishi constant-torque motor, first set "1" in Pr. 71 "applied motor". (This provides a 100% continuous torque characteristic in the low-speed range.) Then, set the rated current of the motor in Pr. 9 "electronic thermal O/L relay". CAUTION •When two or more motors are connected to the inverter, they cannot be protected by the electronic thermal relay function. Install an external thermal relay to each motor. •When a difference between the inverter and motor capacities is large and the setting becomes less than half amount of the inverter rated current, the protective characteristics of the electronic thermal relay function will be deteriorated. In this case, use an external thermal relay. •A special motor cannot be protected by the electronic thermal relay function. Use an external thermal relay. Reference: Motor overload protection characteristics Operation time (s) 50% setting 100% setting (Note 1, 2) (Note 2) 240 30Hz or higher (Note 3) 20Hz 10Hz Protection activating range Range on the right of characteristic curve Normal operating range Range on the left of characteristic curve (Note 1) When you set the 50% value (current value) of the rated inverter output current. Electronic thermal relay (Note 2) The % value denotes the percentage of 120 function for transistor the current value to the rated inverter protection output current, not to the rated motor current. 60 (Note 3) This characteristic curve will be described even under operation of 6Hz or higher 0 50 100 150 180200 when you set the electronic thermal relay Inverter output current (%) function dedicated to the Mitsubishi (% to rated inverter output current) constant-torque motor. 180 73 REVISIONS * The manual number is given on the bottom left of the back cover. *Manual Print Date Number Sep., 2004 IB(NA)-0600210ENG-A First edition Revision For Maximum Safety • Mitsubishi transistorized inverters are not designed or manufactured to be used in equipment or systems in situations that can affect or endanger human life. • When considering this product for operation in special applications such as machinery or systems used in passenger transportation, medical, aerospace, atomic power, electric power, or submarine repeating applications, please contact your nearest Mitsubishi sales representative. • Although this product was manufactured under conditions of strict quality control, you are strongly advised to install safety devices to prevent serious accidents when it is used in facilities where breakdowns of the product are likely to cause a serious accident. • Please do not use this product for loads other than three-phase induction motors.