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Mitsubishi Electronics FR-A500L User's Manual

1. 1100 49 30 d 4 H P L 0 1900 d i i i 439 il 1 iit i Y 152 96 96 156 230 210 505 155 108 96 96 96 104 Bottom View U V W PO Ry Pl P N TERMINAL Detail TERMINAL Detail 37 5 40 0 2 5 C SM 8 35 P P CL WY lt lt CS 4h A B 45 XU XV 37 5 D 35 52 17 51 Y 40 Des 17 5 40 17 5 rt a gt lt gt Units mm 10 INSTALLATION AND WIRING 3 Connection of the power supply and motor R Power Lo supply Ground S T med Li lt gt La 5 lt L gt T lt L gt Ground No fuse breaker The power supply cables must be Connect the motor to U V W connected to R S T lt L4 12 L3 gt In the above connection If they are connected to U V W turning on the forward rotation the inverter will be damaged switch signal rotates the motor in the counterclockwise arrow direction when viewed from the load shaft 4 Connecting the control circuit to a power supply separately from the main circuit If the magnetic contactor MC in the inverter power supply is opened when the protective circuit is operated the inverter control circuit power is lost and the alarm output signal
2. pem Supplied as standard 900 L 1400 4 8 units 60 130 785 350 975 mm T T CABLING HOLE ed WITH COVER FOR MAIN CIRCUIT PN _ 1 e o e e WELD S e ite 8 N 960 zl 1240 o 100 CABLING HOLE WITH Coven FOR CONTROL CIRCUIT BOTTOM VIEW 45 EXPANSION BOLT NOT PROVIDED SPECIFICATIONS Operation panel Parameter unit option FR DU04 FR PU04 094 72283 000 059038 130 51 15 97 24 0 94 8 72 2 83 0 59 0 38 _ g 55 en 8 2 atl e PL dI PW 3 2 4 8 5 amp 5 4hole HELEN EIN ELM M 157 QG Panel cut diagram Q Panel cut diagram 16 5 0 65 068 43750 72 23 75 0 94 11 75 0 46 5 Z 17 0 67 T 1 25 0 05 49 75 0 78 a A ES 17 0 67 13 0 51 1 5 0 06 amp 77 3 5 0 14 46 5 1 83 81 5 3 21 3 25 0 13 54 2 13 i 3 75 0 14 40 1 57 PU connector pin layout Looking from front of inverter unit receptacle side Unit
3. 21 Fan cover bolt 203 N A Cooling fan wires F Terminal FRONT 47 APPENDICES 2 Wiring between cooling fan and terminals is as follows EF 40ETB EF 30ETB EF 40ETB E E K Black W White R Red G Green T4 em 3 3 se e lu Y 2 53 4 CONVERTER CONTROL INVERTER Connect cooling fan wires as above drawing 3 Check the air flow direction OK OK OK ONES Appendix 4 Appendix 4 Installation procedure for brake unit option FR A540L 530K 800K Connect wires as the next drawing Wiring between FR A500L and MT BR5 option Inverter FR A500L 530K 800K e 1 07 0 0 o S o MT BR5 MT BR5 OO TH1 TH1 ol H2 T H2 PR PR E PR PR E OOO PR 1 1 Brake i Unit Option Y Y 0 he _ RESISTOR TEMPERATURE ABNORMAL SIGNALS These signals should be used at Abnormal for input contactor MC trip Set parameter 30 when brake unit is used set to 1 Step3 Set parameter 70 when brake unit is used set to 10 This brake unit and brake resistor are designed at 10 Appendix 5 Appendix 5
4. right of the operation panel as shown on 00 the right The following fault details indicated by the LED display CHARGE A500 1 11 ALARM Brake unit Control Cooling Gat eobling fio 026 Output Right LED power Capacitor Cooling fin pua overheating temperature overcurrent eid overcurrent overheat LI I c c 3 O L O c m CL m A 3 LI O O Ic O O O O O O O O 1 the output overcurrent capacitor overcurrent and gate power supply For example if the display is errors have occurred MEA The inverter output will stop if the brake unit s cooling fin temperature rises above the Brake unit cooling fin overheating oe specified value 3 The inverter output will stop if the ambient temperature of the control board rises above Control board ambient temperature error the specified value The inverter output will stop if the inverter s output current flows above the specified Output overcurrent Value Cooling fan power supply error The inverter output will stop if the cooling fan s power drops below the specified value The inverter will stop if a current exceeding the specified value flows to the main circuit Capacitor overcurrent smoothing capaci
5. A 17 3 OPERATION 4 PARAMETER AS Parameter ot tat Ue es bcea MEE Ses 18 5 PROTECTIVE FUNCTIONS 5 1 Enrors Alanms M Bch Nite ente o sient Eee se e telae 24 5 1 1 Error alarm definitlons core ote b Ro dart 24 5 1 2 Correspondences between digital and actual 28 5 1 3 Alarmi code output uer cem 29 5 1 4 Resetting the een 29 5 2 Troubleshooting ier ederent i een en aeree 30 5 2 1 Checking the operation panel display at alarm stop 30 5 2 2 Faults and check points iiid ie ae alee A teres dite dene sea qo n Duca ze edd 32 5 3 Precautions for Maintenance and Inspection ssssssssssssssssseseeeeemnn 34 5 3 1 Precautions for maintenance and 34 5 9 2 Check fan nein ER een io Pe odo oe Eres uo ee dee ead odd AS aa e ee 34 5 9 9 Periodic inspection or cien ole tt rode et aic eed reap ehe t ebbe e Der oet ete UTERE READERS 34 5 3 4 Insulation resistance test using megger ssssssenennem emen 35 5 3 5 Bielectric
6. Operation 2 Switch power off once then switch it on again Operation 3 Switch on the reset signal RES 29 5 2 Troubleshooting PROTECTIVE FUNCTIONS If any function of the inverter is lost due to occurrence of a fault clear up the cause and make correction in accordance with the following procedure Contact your sales representative if the corresponding fault is not found below the inverter has failed parts have been damaged or any other fault has occurred 5 2 1 Checking the operation panel display at alarm stop The alarm code is displayed on the operation panel to indicate the cause of a faulty operation Clear up the cause and take proper action in accordance with the following table Display Acceleration too fast RI dd Check for output short circuit or ground fault Sudden load change Ee Check for output short circuit or ground fault Keepiload stable Deceleration too fast Increase deceleration time Check for output short circuit or ground fault Mechanical brake of motor operating too fast Check brake operation E OV1 Acceleration too fast Increase acceleration time E OV2 Sudden load change Keep load stable Increase deceleration time Set deceleration time E OV3 Deceleration too fast which matches load GD Reduce braking duty Motor used under overload Reduce load E THT Increase motor and inverter capacities E IPF Check the cause of instantaneous power failure Restore p
7. PARAMETERS Minimum Refer To Setting Range Setting Factory Setting Page Number Increments lt Note9 gt 107 V F4 fourth frequency voltage 0 to 1000V 04V Note 1 108 VIF5 fifth frequency Note 1 0 to 400Hz 9999 0 01Hz 9999 EB Parameter 409 fifth frequency voltage Note 1 7 0 to 3600 sec 0 1 sec 110 Third acceleration deceleration time 0 to 360 sec 9999 0 01 sec 9999 0 to 3600 0 1 sec Third deceleration time 0 to 360 sec 9999 0 01 sec 9999 112 0 to 30 0 9999 5989 1 5 Third VIF base frequency Note 1 Oto 400Hz 9999 999 99 114 Third stall prevention operation current Oto 160 150 S9 115 Third stall prevention operation frequency __0t0400Hz 00 o 116 Third output frequency detection Oto 400Hz 0999 00 9899 0090 r sonner 0651 11 02 19 118 Communication speed 4896192 1 12 99 0 1 data length 8 SEPP ae 10 11 data length 7 1 1 check presence absence pce pm p gt Number of communication retries 010 1 1 1 99 Communication check time interval Fag 0 lt 9999 gt 125 Waltngtime setting Oto 150ms 9009 oms 989 39 124 CR LF presencelabsence selection 012 1 Commercial power supply inverter switch over sequence output terminal 0 1 2 1 116 selection switch over Interlock tne 015 100 0 sec Start waitin
8. mm inches DSG BSDA P5S RDB RDA DSG GDsDB 55 Note 1 not connect the computer s LAN board FAX modem socket or telephone modular connector The electrical specifications differ so the product could be damaged if connected 2 The No 2 and 8 pins P5S are the power supply for the parameter unit Do not use these when carrying out RS 485 communication 46 APPENDICES This chapter provides the appendices for use of this product Always read the instructions before using the equipment Appendix 1 Data Code List TI T1111 1 Refer to FR A540L A560L Appendix 2 List of Parameters Classified by Purpose of Use IITTLITTITIRefer to FR A540L A560L Appendix Installation Procedure for Cooling Fan M7 Appendix 4 Installation Procedure for Brake Unit Option 9 Appendix 5 Shipment Case TLLTELELTLEELELEELTLETITETLTITTTITISO OUTLINE INSTALLATION AND WIRING OPERATION PARAMETERS CHAPTER 5 PROTECTIVE FUNCTIONS CHAPTER 6 SPECIFICATIONS APPENDICES Appendix 3 Appendix 3 Installation procedure for cooling fan FR A540L 530K 800K 1 Install and fix bolts and screws Put cooling fans and fan covers Fix cooling fans and fan covers by M12 bolts Put cooling fan ceilings and fix by M4 screws Screw Cooling fan ceilings 2 T T i
9. Industrial Systems Division Mitsubishi Electric Engineering Co Ltd 2 Model DINV 485CAB Interface built in cable Dia Trend Co Ltd 16 INSTALLATION AND WIRING 2 2 5 Design information 1 For commercial power supply inverter switch over operation provide electrical and mechanical interlocks for MC1 and MC2 designed for commercial power supply inverter switch over When there is a commercial power supply inverter switch over circuit as shown below the inverter will be damaged by leakage current from the power supply due to arcs generated at the time of switch over or chattering caused by a sequence error 2 If the machine must not be restarted when power is restored after a power failure provide a magnetic contactor in the inverter s primary circuit and also make up a sequence which will not switch on the start signal If the start signal start switch remains on after a power failure the inverter will automatically restart as soon as the power is restored 3 When the power supply used with the control circuit is different from the one used with the main circuit make up a circuit which will switch off the main circuit power supply terminals R S T lt L Lo L3 gt when the power supply terminals S1 L44 L21 gt for the control circuit are switched off 4 Since the input signals to the control circuit are on a low level use two parallel micro signal contacts or a twin contact for contact inputs to prevent a cont
10. JOG is assigned 375 900K 530 900K 6 This is not required when the scale is calibrated with the operation panel INSTALLATION AND WIRING 1 Description of main circuit terminals 5 T power input Connect to the commercial power supply Keep these terminals unconnected when lt L4 L2 L3 gt using the high power factor converter MT HC Inverter output Connect a three phase squirrel cage motor Connected to the AC power supply terminals R and S To retain the alarm display and alarm output or when using the high power factor converter MT HC remove the jumpers from terminals R R1 and S S1 and apply external power to these terminals N Optional converter Connect the optional power return converter MT RC or high power factor converter Main S UE et connection MT HC R1 S1 Power supply for Li L21 gt control circuit t eel P P1 DC reactor Connect the enclosed DC reactor 375 450K connection DC reactor is prewired in 530 800K sizes P PR Brake resistor Connect the optional FR BR5 brake resistor For grounding the inverter chassis Must be earthed Note lt gt Terminal names in parentheses are those of the EC version 2 Description of control circuit terminals Turn on the STF signal to start forward rotation and turn it off to When the STF stop Acts as a programmed operation start signal in the and STR signals programmed operation mode Turn on to start and turn of
11. Shipment case example FRONT MEAU Chicago PO Made in japan NW G W 1850 257 x 116 x 256 FR A540L 800K NA panel unit Case 1 2 MEAU Chicago PO Made in japan N W G W 290 kg 192 x 166 x 132 5401 800 Exhaust fans for panel unit Case 2 2 50
12. 2 Temperature applicable for a short period in transit etc 43 SPECIFICATIONS 6 1 3 Outline drawings FR A540L 450K 375K 360 Cabling Hole For main circuit Accessory DC REACTOR for FR A540L 450K 375K 2 M12 bolt This Top attachment should be removed at operating because of air exhaust These Side attachments can be used for fixing this inverter unit Bottom View us J 2 terminal 4 15hole lah ee OSE 240 over Earth terminal M6 screw 4 hole M10 screw 44 41055 3 450 10 SPECIFICATIONS FR A540L 540K 800K DC reactor is internally mounted and wired HOOK FOR TRANSPORTATION Shipped separately AIR EXHAUST AIR EXHAUST E AIR EXHAUST SPACE FOR MAINTENANCE 500 2 800 765 AIR SPACE I e HANDLE WITH KEY DOOR AIR INLET gt FILTER 74 500 rT SPACE FOR MAINTENANCE CAPACITOR REPLACEMENT COVER
13. 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 Check that the CS signal is not off when automatic restart after instantaneous power failure is selected Pr 57 other than 9999 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 Pr 902 to Pr 905 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 5 Others Check that the ALARM lamp is not lit Check that the Pr 15 jog frequency setting is not lower than the Pr 13 starting frequency value 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 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 proper Pr 1 Pr 2 Pr 902 to Pr 905 Pr 19 Check that the input signal lin
14. and external operation MT A100E Mitsubishi large capacity inverter MT A100 series EXCELLENT series CHAPTER1 Meus CHAPTER 2 CHAPTER 3 CHAPTER 4 INSTALLATION AND WIRING OPERATION PARAMETERS CHAPTER 5 PROTECTIVE FUNCTIONS CHAPTER 6 APPENDICES SPECIFICATIONS 11 Pre Operation Information OUTLINE 1 1 1 Precautions for operation Incorrect handling might cause the inverter to operate improperly its life to be reduced considerably or at the worst the inverter to be damaged Handle the inverter properly in accordance with the information in each section as well as the precautions and instructions of this manual to use it correctly This manual is written for the FR A500L series large capacity inverters For handling information on the parameter unit FR PUOA inboard options stand alone options etc refer to the corresponding manuals 1 Unpacking and product check 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 1 Inverter type Rating plate MITSUBISHI INVERTER Inverter type gt mover FR A540L 530K SIAN Seah late Input rating gt N output rating Serial number x Rating plate A MITSUBISHI ELECTRIC CORPORATION JAPAN FR 5401 Symbol Voltage Class 540
15. collector output terminals equipped as standard on the inverter Correlations between alarm definitions and alarm codes are as follows Operation Panel Output Terminal Signal On Off Display OL Alarm Code Alarm Output across B C FR DUO4A 1 Wit RR A 22 1 9 9 o 1 05 o o 1 sme spo 3 k 1 4 Provided Open 7 06 ee ee eee 6 Provided Open 0o 1 1 f 0 EPF 0 1 1 1 7 Provided Open O o 1 9 Provided Open 1 0 A _____ Provided Open O 1 B Provided Open Not provided Provided when OLT is displayed Open E 15 0 E GF 0 quos pog 1 0 E OPT 1 1 1 0 E Provided Open E OP1 to E OP3 1 0 Provided Open E PE Provided Open E PUE Provided Open E RET Provided Open E LF Provided Open E CPU Provided Open E 14 Provided Open Note 0 Output transistor OFF 1 Output transistor ON common terminal SE The alarm output assumes that Pr 195 setting is 99 factory setting 5 1 4 Resetting the inverter The inverter can be reset by performing any of the following operations Note that the electronic overcurrent protection s internal heat calculation value and the number of retries are cleared erased by resetting the inverter Operation 1 Using the operation panel FR DU04 press the RESET key to reset the inverter
16. function is activated refer to 5 2 Troubleshooting and clear up the cause by taking proper action If an alarm stop has occurred the inverter must be reset to restart it 5 1 1 Error alarm definitions Operation 1 OC During During acceleration During Ole Bee Spd constant Overcurrent Speed shut off OC Duri During uring deceleration During stop E OV1 OV During During acceleration During 2 ee Spd constant Regenerative speed overvoltage shut off OV During Baring uri deceleration E OV3 During stop Motor Ovrload Overload shut off electronic overcurrent protection Inv E THT Overload Inverter Inst Pwr Instantaneous power failure E IPF Loss protection Under E UVT Voltage Undervoltage protection H Sink Parameter Display Unit Description FR Duo4 FR PU04 When the inverter output current reaches or exceeds approx 200 of the rated current the protective circuit is activated to stop the inverter output If regenerative energy from the running motor causes the inverter s internal main circuit DC voltage to reach or exceed the specified value the protective circuit is activated to stop the inverter output This may also be activated by a surge voltage generated in the power supply system The electronic overcurrent protection in the inverter detects motor overheat due to overload or cooling capability red
17. of the above devices are installed immediately remove them 6 When rewiring after operation make sure that the POWER lamp has gone off and when more than 10minutes have elapsed after power off check with a tester that the DC bus voltage is zero After that start rewiring work For some time after power off there is a dangerous voltage in the capacitor 7 Top attachments should be removed before operating because of Air exhaust Side attachments can be used for fixing the unit See page 44 Notes on Grounding Leakage currents flow in the inverter To prevent an electric shock the inverter and motor must be grounded grounding resistance 10Q or less e Use the dedicated ground terminal to ground the inverter Do not use the screw in the case chassis etc e The ground cable should have a thickness of 38mm or more and be as short as possible The grounding point should be as close to the inverter as possible INSTALLATION AND WIRING 2 Terminal block layout In the main circuit of the inverter the terminals are arranged as shown below FR A540L 530K 800K 800 Left Side Right Side MAIN CIRCUIT TERMINAL Detail INSTALLATION AND WIRING FR A540L 375K 450K
18. only Approximately 10DVC at Across AM 5 maximum frequency without frequency meter Start signal Across STF STR RH RM RL RT AU STOP CS SD 20 to 30VDC when open ON voltage 1V or less Continuity check Note 2 Alarm signal Across A C Moving coil type lt AtOFF gt AtON Across B C such as tester Across A C Discontinuity Continuity Across B C Continuity Discontinuity Note 1 Accurate data will not be obtained by a tester 2 When Pr 195 A B C terminal function selection setting is positive logic SD is common 40 6 SPECIFICATIONS This chapter provides the specifications of this product Always read the instructions before using the equipment 6 1 Standard Specifications 141 OUTLINE INSTALLATION AND WIRING OPERATION PARAMETERS CHAPTER 5 PROTECTIVE FUNCTIONS CHAPTER 6 APPENDICES 6 1 Standard specification SPECIFICATIONS 6 1 1 Model specifications Note 8 Note 8 xs oam om ee ew we s Applicable motor Constant torque 375 450 530 ero 70 80 capacity KW 7 Variable torque 450 sso eo 670 750 Rated capacity HP 8001 mo am so mom Teo 00 Tm cent ree rr se owe nm see Variable torque 866 1010 1152 1296 1534 178 150 60 sec 200 Constant torque 0 5 sec inverse time 150 60 sec inverse time character
19. panel or parameter unit using a connection cable lt Recommended cable connector gt Parameter unit connection cable FR CB2 option or the following connector and cable Connector RJ45 connector Example 5 554720 3 Nippon AMP Cable Cable conforming to EIA568 e g 10BASE T cable Example SGLPEV 0 5mmx 4P MITSUBISHI CABLE INDUSTRIES LTD Note The maximum wiring length is 20m 65 62 feet 2 For RS 485 communication With the operation panel disconnected the PU connector can be used for communication operation from a personal computer etc lt PU connector pin outs gt Viewed from the inverter receptacle side front o SG SDA 55 RDB 8 RDA o SG SDB P5S Note 1 Do not connect the PU connector to the computer s LAN board FAX modem socket or telephone modular connector Otherwise the product may be damaged due to electrical specification differences 2 Pins 2 and 8 P5S provide power to the operation unit or parameter unit Do not use these pins for RS 485 communication Use the connector and cable as detailed below Connector RJ45 connector Example 5 554720 3 Nippon AMP Cable Cable conforming to EIA568 e g 10BASE T cable Example SGLPEV 0 5mmx 4P MITSUBISHI CABLE INDUSTRIES LTD When the communication board of the personal computer has the RS 232C specifications prepare an RS 485 RS 232C converter Example of converter 1 Model FA T RS40 Converter
20. speed setting speed 7 28 Multi speed input compensation 01 1 Acceleration deceleration pattern 0123 1 Standard operation functions 1 1 Speed display 1 9 To 41 Uprto frequency sensit Output frequency detection for reverse 0 to 400Hz 9999 0 01Hz rotation terminal functions 0 to 3600 0 1 sec Second acceleration deceleration time 0 to 360 sec 0 01 sec 5 sec 0 to 3600 0 1 sec Second deceleration time 0 to 360 sec 9999 0 01 sec 9999 Second torque boost Note 1 0 to 30 9999 9999 0 4 Second V F base frequency Note 1 0 to 400Hz 9999 0 01Hz 9999 Second stall prevention operation current 0 to 150 150 Second stall prevention operation 0 to 400Hz 9999 0 01Hz 65 frequency Second output frequency detection 0 to 400Hz 0 01Hz Second functions 18 Display functions Automatic restart functions Additional function Operation selection functions Motor constants 5 point flexible V F characteristics PARAMETERS Minimum Refer To Parameter Setting Range Setting Factory Setting Page Number Increments lt Note9 gt 2 0 5 to 14 17 18 20 3 PU level display data selection 0 to 3 5 to 14 17 18 1 1 67 5 1 to 3 5 to 14 Frequency monitoring reference 0 to 400Hz 0 01Hz 60Hz 50Hz 69 56 Current monitoring reference 0 to 3600A 0 1A Rated output current 69 57 Restart coast
21. strengthitest teet estre C Pe ER Pep epe es 35 5 3 6 Replacement Of parts nite t et eie een Reape eaten a dene 38 5 3 7 Measurement of main circuit voltages currents and power 39 6 SPECIFICATIONS 0 1 Standard SpecitiGatiOnS Em 41 6 1 1 Model specifications cccccccccccccccceeeeeeeeceeeeeeeeeeeeeeeaaeeeeeeeeeseeeeaaaeeeeeeeeeseceseeeeeeesseseneeeeeees 41 6 1 2 Common specifications 42 6 1 3 OUTING drawings tate te rta eat d 44 APPENDICES PejerztueD esM 47 ADDENGIX4 E E EE 49 Appendixb ce amd ert es sce heo ehe nc ce ho Ert Lees tL D Leti tl 50 1 OUTLINE This chapter gives information on the basic outline of this product Always read the instructions in this chapter before using the equipment 1 1 Pre Operation Information 1111111111111 1 2 Basic Configuration Abbreviations DU Operation panel FR DU04 PU Operation panel FR DU04 and parameter unit FR PU04 Inverter Mitsubishi Large Capacity inverter FR A500L series FR A500L Mitsubishi Large Capacity inverter FR A500L series Pr Parameter number PU operation Operation using the PU FR DU04 FR PU04 External operation Operation using the control circuit signals Combined operation Operation using both the PU FR DU04 FR PU04
22. the power is restored after an instantaneous power failure Note 186 change that this operation requires restart parameters to be set When the terminal functions inverter is shipped from the factory it is set to disallow restart Contact input Common terminal for the terminal FM common sink Common output terminal for 24VDC 0 1A power PC terminal 24VDC power and When transistor output open collector output such as a programmable controller is external transistor connected connect the external power supply common for transistor output to this common terminal to prevent a fault caused by leakage current This terminal can be used as a Contact input 24VDC 0 1A power output When source logic has been selected this terminal common source Serves as a contact input common JOG mode selection 0 c Contacts e g start function setting Automatic restart after instantaneous power failure selection INSTALLATION AND WIRING 10VDC permissible load current When the frequency setting potentiometer is 10 connected in the factory set state connect it to Frequency setting terminal 10 power supply 5VDC permissible load current 10mA When it is connected to terminal 10E change the input specifications of terminal 2 By entering 0 to 5VDC 0 to 10VDC the maximum output frequency is reached at 5V Frequency setting or 10V and I O are proportional Switch between input 0 t
23. to each other or earthed 2 Use shielded or twisted cables for connection to the control circuit terminals and run them away from the main and power circuits including the 200V relay sequence circuit 3 The frequency input signals to the control circuit are micro currents When contacts are required use two or more parallel micro signal contacts or a twin contact to prevent a contact fault 4 It is recommended to use the cables of 0 75mm gauge for connection to the control circuit terminals If the cable gauge used is 1 25mm or more the front cover may be lifted when there are many cables running or the cables are run improperly resulting in an operation panel or parameter unit contact fault 2 Terminal block layout NA version OR Version In the control circuit of the inverter the terminals are arranged as shown below Terminal screw size M3 5 EC version Terminal screw size M3 1111 Te De Te T Te e Tom En eee T Tn Wiring procedure 1 Forthe wiring of the control circuit strip the sheaths of the cables and use them as they are Strip the sheath to the following dimension If too much is stripped this may cause a short circuit with the neighboring cable If too little stripped this may cause cable disconnection 6mm 1mm 2 Loosen the terminal screw and insert the cable into the terminal 3 Tighten the screw to the specified torque Undertigthening can cause cab
24. 1 400 class 2 Accessory Instruction manual Symbol Applicable Motor Capacity 530K Indicates capacity in kW Symbol Specifications U S specifications If you have found any discrepancy damage etc please contact your sales representative 2 Preparations of instruments and parts required for operation Instruments and parts to be prepared depend on how the inverter is operated Prepare equipment and parts as necessary 3 Installation To operate the inverter with high performance for a long time install the inverter in a proper place in a correct direction and with proper clearances 4 Wirin Connect the power supply motor and operation signals control signals to the terminal block Note that incorrect connection may damage the inverter and peripheral devices See page 8 1 2 Basic Configuration OUTLINE 1 2 1 Basic configuration The following devices are required to operate the inverter Proper peripheral devices must be selected and correct connections made to ensure proper operation Incorrect system configuration and connections can cause the inverter to operate improperly its life to be reduced considerably and in the worst case the inverter to be damaged Please handle the inverter properly in accordance with the information in each section as well as the precautions and instructions of this manual For connections of the peripheral devices refer to the correspondi
25. 5 Avoid high temperature and high humidity Avoid places where the inverter is subjected to direct sunlight high temperature and high humidity Note The cooling section outside the enclosure has the cooling fan Do not use the inverter in any environment where it is exposed to waterdrops oil mist dust etc 6 Avoid places where the inverter is exposed to oil mist flammable gases fluff dust dirt etc Install the inverter in a clean place or inside a totally enclosed panel which does not accept any suspended matter 7 Note the cooling method when the inverter is installed in an enclosure When an inverter is mounted in an enclosure the ventilation fans of the inverter and enclosure must be carefully positioned to keep the ambient temperature of the inverter below the permissible value If they are installed in improper positions the rise in ambient temperature will result in reduced performance of the inverter 8 Secure the inverter vertically with bolts Install the inverter on an installation surface securely and vertically with screws or bolts INSTALLATION AND WIRING 3 Note on ambient temperatures FR A540L 530 800K m e 40 C at 5cm 1 97 inch FR A540L 375 450K Leave sufficient clearances above Cooli ooling air and under the 5 inverter to ensute adeguate ventilation NNNNNNNNNNNNNNNNNNNNNN 7 87 inches or more Cooling fan built in tha i
26. MITSUBISHI LARGE CAPACITY INVERTER FR A500L HIGH PERFORMANCE amp HIGH FUNCTIONS FR AS40L 375K 800K NA INSTRUCTION MANUAL Supplementary Manual Refer to Operation Instruction Manual for FR A500L 4 MITSUBISHI aa ELECTRIC Thank you for choosing this Mitsubishi Large Capacity Inverter This instruction manual gives handling information and precautions for use of this equipment Incorrect handling might cause an unexpected fault Before using the inverter please read this manual carefully to use the equipment to its optimum This manual describes the parts which are different from the FR A500L chassis drive up to 280kw Please refer to the FR A500L instruction manual for further details 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 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 the safety instruction levels are classified into WARNING and CAUTION Assumes that incorrect handling may cause hazardous conditions resulting in INWARNING death or severe injury CAUTION Assumes that incorrect handling may cause hazardous conditions resulting in medium or slight injury or may cause physical damag
27. NCTIONS 5 3 7 Measurement of main circuit voltages currents and power Measurement of voltages and currents Since the voltages and currents on the inverter power supply and output sides include harmonics accurate measurement depends on the instruments used and circuits measured When instruments for commercial frequency are used for measurement measure the following circuits using the instruments given on the next page Input voltage Output voltage v Input current Output current Inverter To motor supply 3 phase power Instrument types Typical Measuring Points and Instruments Note Use an FFT to measure the output voltage accurately Accurate measurement cannot be made if you use a tester or general measuring instruments 39 PROTECTIVE FUNCTIONS Measuring Points and Instruments Remarks Reference Measured Value Commercial power supply ee Moving iron type AC voltmeter Within permissible voltage Ed rd fluctuation Refer to Page 400 Power supply side R S and T line currents UE At R S and T and across R S Power supply side power S T and T R Electrodynamic type single Pa W11 W12 W13 P1 lt At L4 L2 and L3 and across L4 phase wattmeter 3 wattmeter method Lo Lo L3 and L3 L41 gt Calculate after measuring power supply voltage power supply side current and power supply side power I
28. PECIFICATIONS 6 1 2 Common specifications Control specifications Operational specifications Soft PWM control high carrier frequency PWM control V F control or advanced magnetic flux Control system vector control can be selected Output frequency range 0 2 to 400 2 Frequency 0 015Hz 60Hz terminal 2 input 12 bits O to 10V 11 bits O to 5V terminal 1 input 12 bits 10 to setting Analog input 470V 11 bits _5 to 5V resolution Digital input 0 01 2 Within 0 2 of maximum output frequency 25 10 for analog input within 0 0196 of set output frequency for digital input Voltage frequency Base frequency set as required between 0 and 400Hz Constant torque or variable torque characteristic pattern can be selected Starting torque 150 At 0 5Hz for advanced magnetic flux vector control Torque boost Manual torque boost Acceleration deceleration 0 to 3600 sec acceleration and deceleration can be set individually linear or S pattern time setting acceleration deceleration mode can be selected Frequency accuracy DC dynamic brake Operation frequency 0 to 120Hz operation time 0 to 10 sec voltage 0 to 30 variable Stall prevention operation evel Operation current level can be set 0 to 150 variable presence or absence can be selected Analog input 0 to 5VDC 0 to 10VDC 0 to 10VDC 4 to 20mADC 3 digit BCD or 12 bit binary using operation panel or parameter unit when the FR A5AX option is
29. act fault 5 Do not apply a large voltage to the contact input terminals e g STF of the control circuit 6 Do not apply a voltage directly to the alarm output signal terminals A B C Always apply a voltage to these terminals via a relay coil lamp etc 7 Make sure that the specifications and rating match the system requirements 1 Commercial power supply inverter switch over 2 Low level signal contacts MC1 Interlock x 1 Power j supply w eS SoS id Sneak current Inverter Low level signal contacts Twin contact 17 CHAPTER 3 OPERATION This chapter provides the basic operation information for use of this product Always read this chapter before using the equipment 3 1 Pre Operation Information TTTTTTT Refer FR A540L A560L 3 2 Operation TITITITITITITITILTITI Refer to FR A540L A560L OUTLINE INSTALLATION AND WIRING OPERATION PARAMETERS CHAPTER 5 PROTECTIVE FUNCTIONS CHAPTER 6 SPECIFICATIONS APPENDICES 4 PARAMETERS This chapter explains the parameters of this product Always read the instructions before using the equipment 4 1 Parameter List 11111118 4 2 Parameter Function Details TTT TT Refer to FR A540L A560L Note By making parameter settings you can change the functions of contact input terminals RL RM RH RT AU CS and open collector output terminals RUN SU IPF OL FU Therefore signal names corresponding to the functions ar
30. age 3 hygrometer dust dirt etc Ambient humidity recorder 90 or less non condensing General Check for unusual Visual and auditory Measure voltage Within permissible Check that main circuit across inverter AC voltage Tester digital voltage is normal terminals R S T fluctuation multimeter 81545155 Refer to page 40 1 Check with megger 1 Disconnect all 1 5M Q or more across main circuit cables from 2 3 No fault terminals and inverter and ground terminal measure across 2 Check for loose terminals R S T screws and bolts U V W L Lo 500VDC class 3 Check for overheat La U V W gt and megger ing of each part ground terminal Mal 4 Clean with megger 2 Re tighten 3 Visual check General 1 Check conductors 1 2 Visual check 1 2 No fault for distortion Conductors 2 Check cable sheaths for breakage ee Check for damage Visual check No fault 231 35 PROTECTIVE FUNCTIONS Daily and Periodic Inspection Inspection teni Description Inverter module Check resistance Converter across terminals module 1 Check for liquid leakage 2 Check for safety Smoothing valve projection and capacitor bulge 3 Measure electrostatic capacity 1 Check for chatter during operation Relay 2 Check for rough surface on contacts 1 Check for crack in resistor insulation 2 Check for op
31. and inverter 2 INSTALLATION AND WIRING This chapter gives information on the basic installation and wiring of this product Always read the instructions in this chapter before using the equipment 2 1 Installation TTT 3 2 2 Wiring TTTTTTTTTTTTTTTTTTTTITITITITITTTTITI 5 OUTLINE INSTALLATION AND WIRING OPERATION APPENDICES PARAMETERS PROTECTIVE FUNCTIONS SPECIFICATIONS 2 1 Installation 2 1 1 Instructions for installation 1 Handle the unit carefully The inverter uses plastic parts Handle it gently to protect it from damage Also hold the unit with even strength and do not apply too much strength to the front cover alone 2 Install the inverter where it is not subjected to vibration Note the vibration of a cart press etc 3 Note on ambient temperature The inverter life is under great influence of ambient temperature In the place of installation ambient temperature must be within the permissible range 10 C to 40 C 14 F to 104 F Check that the ambient temperature is within that range in the positions shown in figure 3 For FR A540L 375 450K at constant torque CT rating maximum ambient temperature can be 50 C 122 F 4 Install the inverter on a non combustible surface The inverter will be very hot maximum about 150 C 302 F Install it on a non combustible surface e g metal Also leave sufficient clearances around the inverter
32. and replace the DC fuse 30 PROTECTIVE FUNCTIONS Operation Panel Check Point Display Brake unit cooling fin overheating Control ambient temperature error Output over current Cooling fan power supply error Capacitor overcurrent Cooling fin overheat Gate power supply error board Is the usage frequency of the brake unit appropriate Are the cooling fins clogged Is there any error in the inverter unit cooling fan Is there an error in the cooling fan Is the ambient temperature too high Is there an output short circuit or ground fault Check the motor winding and insulation resistance Was rapid acceleration attempted Did the load fluctuate suddenly Was rapid deceleration attempted Were the motor s mechanical brakes applied too quickly Is the cooling fan s power supply output short circuited Is the cooling fan s power supply abnormal Is the fuse blown Is the DC circuit short circuited Is there an output short circuit or ground fault Check the motor winding and insulation resistance Is there an error in the cooling fan Are the cooling fins clogged Is the ambient temperature too high Is the gate output short circuited Is there an error in the control power supply board Reduce the load Reduce the braking frequency Clean the cooling fins Replace the cooling fan Replace the cooling fan Keep the ambient temperature within the specificatio
33. at generated may increase The inverter output will be stopped if the power supply voltage drops to 150V approx 300V for 400V class or less The undervoltage protection function will activate if the DC reactor accessory is not used If the cooling fin overheats the temperature sensor is activated to stop the inverter output 24 PROTECTIVE FUNCTIONS Operation Panel Display FR DU04 E OHT E OLT When stall prevention operation has reduced the running frequency to 0 OL during stall prevention operation E OP1 to OP3 Memry PU Leave Parameter Unit FR PU04 OH Fault Stll Prev STP OL shown during stall prevention operation Option slot alarm 1to3 Description This function stops the inverter output if a ground fault occurs in the inverter s output load side and a ground fault current flows A ground fault occurring at low ground resistance may activate the overcurrent protection OC1 to OC3 If the external thermal relay designed for motor overheat protection or the internally mounted temperature relay in the motor switches on relay contacts open the inverter output can be stopped if those contacts had been entered into the inverter If the relay contacts are reset automatically the inverter will not restart unless it is reset If a current not less than 15096 Note 4 of the rated inverter current flows in the motor this function lowers the frequency until the
34. ation speed Maximum 19200 baud rates Overall length 500m Communication 9 g c o 2 2 D 9 lt Q t 0 a Note1 Low indicates that the open collector outputting transistor is on conducts High indicates that the transistor is off does not conduct Note2 Not output while the inverter is reset INSTALLATION AND WIRING 2 2 2 Wiring of the main circuit 1 Wiring instructions 1 Power must not be applied to the output terminals U V W of the inverter Otherwise the inverter will be damaged 2 After wiring wire off cuts must not be left in the inverter Wire off cuts can cause an alarm failure or malfunction Always keep the inverter clean 3 Use thick cables to make a voltage drop of 2 or less If the wiring distance is long between the inverter and motor a main circuit cable voltage drop will cause the motor torque to decrease especially at the output of a low frequency 4 Electromagnetic wave interference The input output main circuit of the inverter includes harmonic components which may interfere with the communication devices such as AM radios used near the inverter In this case use shielded wire cables as the power cable 5 Do not install a power capacitor surge suppressor or radio noise filter FR BIF option in the output side of the inverter This will cause the inverter to trip or the capacitor and surge suppressor to be damaged If any
35. c 2 Screws and 5 11111111 parts may become loose due to vibration temperature changes etc Check that they are tightened securely and retighten as necessary 3 Conductors and insulating materials Check for corrosion and damage 4 Insulation resistance Measure 5 Cooling fan smoothing capacitor relay Check and change if necessary PROTECTIVE FUNCTIONS 5 3 4 Insulation resistance test using megger 1 Before performing the insulation resistance test using a megger 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 a 500 megger R lt L gt Inverter 5412 T lt L gt Power Ground terminal 5 3 5 Dielectric strength test Do not conduct a dielectric strength test The inverter s main circuit uses semiconductors which may be deteriorated if a pressure test is made Daily and Periodic Inspection inspection Description Method Criterion Instrument Item Daily Ambient temperature S ifo ding Check ambient 10 C to 40 C Thermometer Environment temperature humidity Refer to p
36. c capacitor is used for smoothing the DC in the main circuit and an aluminum electrolytic capacitor is also used for stabilizing the control power in the control circuit Their characteristics are adversely affected by ripple current etc When the inverter is operated in an ordinary air conditioned environment change the capacitors about every 5 years When 5 years have elapsed the capacitors will deteriorate more rapidly Check the capacitors at least every year less than six months if their life will be expired soon Check the following 1 Case side faces and bottom face for expansion 2 Sealing plate for remarkable warping and extreme cracks 3 Explosion proof valve for excessive valve expansion and operation 4 Appearance external cracks discoloration leakage When the measured capacitance of the capacitor has reduced below 85 of the rating change the capacitor 3 Relays To prevent a contact fault etc relays must be changed according to the number of accumulative switching times switching life See the following table for the inverter parts replacement guide Lamps and other short life parts must also be changed during periodic inspection Replacement Parts of the Inverter Smoothing capacitor in main circuit Change as required Smoothing capacitor on control board Change the board as required Smoothing capacitor on cooling fan power supply Change the power supply as required 38 PROTECTIVE FU
37. cannot be kept on To keep the alarm signal on terminals R1 and S1 are available In this case connect the power supply terminals R1 and S1 lt L and 154 of the control circuit to the primary side of the MC Connection procedure R1 51 lt gt Power supply terminal block for control circuit Power supply terminal x block for control circuit 1 Loosen the upper screws 2 Remove the lower screws 3 Pull out and remove the jumper 4 Connect the separate power supply cables for control circuit to upper terminals R1 S1 L44 L2 Note 4 Main power supply When the main circuit power S T L5 La is on do not switch off the control power terminals S1 L44 112 Otherwise the inverter may be damaged When using a separate power supply the jumpers across R R1 5 51 L Li and Lz L4 must be removed Otherwise the inverter may be damaged For a different power supply system which takes the power of the control circuit from other than the primary side of the MC the voltage should be equal to the main circuit voltage The power supply cables must not be connected to the lower terminals If connected the inverter may be damaged 11 INSTALLATION AND WIRING 2 2 3 Wiring of the control circuit 1 Wiring instructions 1 Terminals SD SE and 5 are common to the I O signals and isolated from each other These common terminals must not be connected
38. ding of meters on panel 1 Auditory sensory visual checks 2 Check for unusual odor due to overheating damage etc 1 Disconnect cables from U V W including motor cables Criterion Instrument See the following Analog tester pages 1 2 No fault 3 8596 or more of rated capacity 1 No fault 2 No fault 1 No fault 2 Error should be within 10 of indicated resistance value 1 Phase to phase voltage balance within 8V 400 Digital 2 Fault must multimeter occur because rectifier type ofsequence voltmeter Tester digital multimeter 1 Smooth rotation 2 No fault 24V x 2 4V 1 Check that lamps are lit Must satisfy specified and management values 1 2 No fault 1 5M or more 500V megger Voltmeter ammeter etc PROTECTIVE FUNCTIONS Checking the inverter and converter modules lt Preparation gt 1 Disconnect the external power supply cables S T Li Lz L3 and motor cables U V W 2 Prepare a tester Use 1000 range Checking method Change the polarity of the tester alternately at the inverter terminals R S T V W P and N lt Ly L2 Ls U V W and gt and check for continuity Before measurement check that the smoothing capacitor is discharged Atthe time of continuity the measured value is several to several ten s of ohms depending on the module type circuit tester
39. e only Note that 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 SAFETY INSTRUCTIONS 1 Electric Shock Prevention While power is on or when the inverter is running do not open the front door You may get an electric shock Do not run the inverter with the front door opened Contact with the exposed high voltage terminals or charging part of circuitry will cause an electric shock If power is off do not open the front door except for wiring or periodic inspection You may access the charged inverter circuits and get an electric shock Before starting wiring or inspection switch power off wait for more at least 10 minutes and check for the presence of any residual voltage with meter see chapter 2 for further details etc 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 Operate the switches 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 Install the inverter on an incombustible cubicle Installing the inverter directly on or near a combustible surface could lead to a fire If the inverter has become faulty switch off the i
40. e used in the description of this chapter except in the wiring examples Note that they are not terminal names The setting in brackets refer to the EC versions default settings CHAPTER 1 OUTLINE INSTALLATION AND WIRING CHAPTER 2 CHAPTER 3 OPERATION CHAPTER 4 BAA aS CHAPTER 5 PROTECTIVE FUNCTIONS CHAPTER 6 SPECIFICATIONS APPENDICES 4 1 Parameter List PARAMETERS Minimum Refer To Parameter Setting Range Setting Factory Setting Page Number Increments lt Note9 gt 0 Torque boost Note 1 30 1 Maximum frequency 0 to 60Hz 0 01Hz 60Hz 49 Multi speed setting high speed Multi speed setting middle speed 6 MWulkspeed setting speed 0 to 3600 0 1 sec 7 1 0 to 3600 0 1 sec Em Electronic thermal O L relay 0 to 3600A Rated a 10 3Hz 54 DC injection brake operation frequency 0 to 120Hz 9999 0 01Hz 14 Load pattem selection Note ows 1 gt Ts 0 to 3600 0 1 sec MRS input selection 02 1 1 18 High speed maximum frequency 0 to 400Hz Base frequency voltage Note 1 0 to 1000V 8888 9999 9999 8888 57 Acceleration deceleration reference 4 to 400Hz 0 01Hz 60Hz lt 50Hz gt EN frequency Acceleration deceleration time 21 0 1 increments Basic functions 57 1 57 Stall prevention operation level 0 to 150 9999 01 1509 58 58 Multi speed setting speed 6 Multi
41. en Resistor cable 1 Check balance of output voltages across phases with Control inverter operated circuit i independently Protective 2 Perform sequence circuit protective operation test to make sure of no fault in protective and display circuits 1 Check for unusual Cooling fan vibration and noise 2 Check for loose connection Cooling fan power supply 1 Check if LED lamp Display is blown 2 Clean Display p Check that reading is normal Meter 1 Check for unusual vibration and noise 2 Check for unusual General odor Motor 1 Check with megger across terminals and ground terminal Main circuit Is the power supply s output voltage correct Insulation resistance Interval EU Vest am 36 Method Disconnect cables from inverter and measure across terminals R S T P N U V W P N lt Lo Ls and U V W gt with tester range of 1000 1 2 Visual check 3 Measure with capacity meter 1 Auditory check 2 Visual check 1 Visual check Cement resistor wire wound resistor 2 Disconnect one end and measure with tester 1 Measure voltage across inverter output terminals U V W 2 Simulatively connect or disconnect inverter protective circuit output terminals 1 Turn by hand with power off 2 Re tighten Measure with a tester 1 Light indicator lamps on panel 2 Clean with rag Check rea
42. enance inspection and parts replacement N CAUTION Do not carry out a megger insulation resistance test on the control circuit of the inverter 7 Disposing of the inverter N CAUTION 8 General instructions Many of the diagrams and drawings in this instruction manual show the inverter without a cover or partially open NEVER run the inverter like this Always replace the cover and follow this instruction manual when operating the inverter CONTENTS 1 OUTLINE 1 1 Pre Operation Information cccccccccceeeeeecceeeeeeeeeeeeeeeaeeeeeeeeeetegecaaeeeeeeeeesedecceaeeeeeeeeteseeeeeeeeeeeees 1 1 1 1 amp e a eaa aa a e nennen 1 1 2 Basic Configuration 2 1 2 1 BASIC COMPOUPATON e E 2 2 INSTALLATION AND WIRING PME IT 3 2 1 1 Instructions for installation FASENE AAAA SAUER 3 2 25 5 2 2 1 Terminal connection diagram iesse nee E AE E A EE A E 5 2 2 2 Wiring of WIGI Lae Ae E E NEO AS AE EOE 8 2 2 3 Wiring of the control circuit isse cicseee a A A 12 2 2 4 Connection to the PUCONNECtO 16 2 2 5 Design information
43. es are not affected by external noise Use shielded cables Check that the load is not too heavy 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 Pr 0 Pr 46 Pr 112 setting is not too large to activate the stall function 32 PROTECTIVE FUNCTIONS 5 Motor current is large Check that the load is not too heavy Check that the torque boost Pr 0 Pr 46 Pr 112 setting is not too large 6 Speed does not increase Check that the maximum frequency Pr 1 setting is correct Check that the load is not too heavy In agitators etc load may become heavy in winter Check that the torque boost Pr 0 Pr 46 Pr 112 setting is not too large to activate the stall prevention function 7 Speed varies during operation During operation under advanced magnetic flux vector control 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 induced noise 3 Others Check that the settings of the applied motor capacity Pr 80 and the number of applied motor poles Pr 81 are correct for the inverte
44. f to are turned on stop simultaneously 1 the stop STR Revers rotation start Ded on the STR signal to start reverse rotation and turn it off to command is given STOP ec o Turn on the STOP signal to select the self holding of the start signal RHO RMG RL Multi speed selection Use the RH RM and RL signals as appropriate to select multiple speeds JOG Forward rotation start This terminal connected internally can not be used by the Input terminal customer 530 800K this signal is assigned in Factory function selection Turn on the RT signal to select the second acceleration Pr 180 to Second acceleration deceleration time When the second functions such as second Pr 186 change deceleration time torque boost and second V F base frequency functions have terminal functions selection been set these functions can also be selected by turning on the RT signal MRS Output sto Turn on the MRS signal 20ms or longer to stop the inverter output Used to shut off the inverter output to bring the motor to a stop by the magnetic brake Used to reset the protective circuit activated Turn on the RES signal for more than 0 1 RES Reset A sec then turn it off AU Current input Only when the AU signal is turned on the inverter can be selection operated with the 4 20mADC frequency setting signal Input terminal function selection With the CS signal on restart can be made automatically when Pr 180 to Pr
45. g for 530K 800K 10 C to 40 C Ambient 14 F to 104 F non freezing at VT rating for 375K 450K temperature 10 C to 50 C 14 F to 122 F non freezing at CT rating for 375K 450K 90 RH or less non condensing Storage 20 C to 65 C 4 F to 149 F temperature Altitude vibration Maximum 1000m 3280 80feet above sea level for standard operation pessum After 1000 derate by 3 for every extra 500m up to 2500m 91 For transportation 20 C to 65 C 4 F to 149 F Relative fumidity 90 or less to 106 2 Wiring Do not fit capacitive equipment such as power factor correction capacitor noise filter 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 Check all parameters and ensure that the machine will not be damaged by sudden start up 4 Operation 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 e
46. g ime 010 100 0 sec 138 Commercial power supply inverter 0 1 1 116 switch over selection at alarm occurrence 139 Automatic inverter commercial power 0 to 60 00Hz 9999 0 01Hz 9999 116 supply switch over frequency 140 Backlash acceleration stopping 0 to 400Hz 0 01Hz 1 00Hz 119 frequency Note 7 141 Backlash acceleration stopping time 0 to 360 sec 0 1 sec 0 5 sec 119 Note 7 142 Backlash deceleration stopping 0 to 400Hz 0 01Hz 1 00Hz 119 frequency Note 7 characteristics 0 to 1000V 0 1V 5 point flexible V F Third functions PID control Communication functions Commercial power supply inverter switch over Backlash deceleration stopping time 0 to 360 sec 035556 119 7 0 2 4 6 8 10 102 Speed setting switch over 104 106 108 110 1 119 Display Backlash Stall prevention level at OV input 0 to 150 0 1 120 58 Stall prevention level at 10V input 0 to 150 0 1 150 58 Additional functions 20 PARAMETERS Minimum Refer To py 2 ipid 227 Nat Number Increments lt Note9 gt 120 150 Output current detection eve 0102000 016 1506 120 Output current detection perod 01010sec o 12 prevention operation 155 RTactivated condition ow 1 gt Stall prevention operation selection 01031 100 1 0o 122 OL signal waiting time 01025 999 otse o 124 A 1 to 3 5 to 14 Sub func
47. ing time 0 to 30 sec 9999 9999 pw fede fe Ooo o Jan 60 inteligent mode selection _ ows 1 61 Reference for intelligent mode 0 to 3600A 9999 0 1A 9999 75 0 10 150 9999 6 ows 1 1 o 60Hz lt 50Hz gt 062 201 starting frequency 67 Number ofretries at alarm occurrence Oto fotortomo o 7 68 Retrywaitingtime 0 10 otses isc 76 69 Rewcomtdspaysasue 0 0 19 71 Amledmoor 0 1 o Te 73 05V0 0Vseecin 010510015 1 89 detection PU stop selection 76 Mamcodeowpuseecin 0123 1 o Ts 77 Parameterwrte disable selection 012 9 fa Reverse rotation prevention selection 0 12 1 gt 85 Operation mode selection ows o 0169 Motor constant R1 Note 6 Motor constant L1 Note 6 Online auto tuning selection 1 Auto tuning setting status 1 100 VIF1 first frequency Note 1 0 to 400Hz 9999 0 01Hz 39 Speedconoigan 0102095 35 100 101 1 first frequency voltage 0 to 1000V 04V Note 1 2 second frequency Note 1 0 to 400Hz 9999 0 01Hz 103 V F2 second frequency voltage 0 to 1000V 1 third frequency Note 1 0 to 400Hz 9999 0 01Hz VIF3 third frequency voltage Note 1 0 to 1000V VIF4 fourth frequency Note 1 0 to 400Hz 9999 0 01Hz 19
48. istics characteristics 120 60 sec 150 Variable torque 0 5 sec inverse time 120 60 sec inverse time characteristics characteristics capacity kVA variable 080 e wer vxo 1920 Open P20 10 C to 40 C 14 F to 104 F at VT 10 C to 50 C 14 F to 122 F at CT Cooling method Forced air cooling Approx weight kg 1b 1060 1060 1100 1100 1200 1078 m 2332 2332 2420 2420 2640 The applicable motor capacity indicated is the maximum capacity applicable when Mitsubishi 4 pole standard motor is used For A540K The rated output capacity indicated is based on for A540L The overload capacity indicated in is the ratio of the overload current to the inverter s rated current For repeated duty allow time for the inverter and motor to return to or below the temperatures under 100 load The maximum output voltage cannot exceed the power supply voltage The maximum output voltage may be set as desired below the power supply voltage The power supply capacity changes with the values of the power supply side inverter impedance including those of the input reactor and cables Overload capacity Power supply Ambient temperature 10 C to 40 C 14 F to 104 F For use in Variable torque mode refer to Pr 570 For inverter environmental conditions including ambient temperature please check page A 3 Preliminary ratings 41 S
49. le disconnection or malfunction Overtightening can cause a short circuit or malfunction due to the screw or unit damaged Tightening torque 5 to 6 Note Wire the stripped cable by twisting it to prevent it from becoming loose Do not plate the cable with solder Note 1 Use a NFB No fuse breakers or fuse on the inverter input primary side 2 Make sure that the control circuit terminal wiring does not touch power circuit terminals or screws or conducting power circuit 12 INSTALLATION AND WIRING 3 Changing the control logic The input signals are set to sink logic for the NA version and to source logic for the EC version To change the control logic the connector on the back of the control circuit terminal block must be moved to the other position The output signals may be used in either the sink or source logic independently of the connector position 1 Loosen the two mounting screws in both ends of the control circuit terminal block The screws cannot be removed With both hands pull down the terminal block from the back of the control circuit terminals 2 Remove the connector in the sink logic position on the back surface of the control circuit terminal block and fit it to the source logic position EC version NA version 3 Using care not to bend the pins of the control circuit connector reinstall the con
50. le load 24VDC 0 1A Switched low when the stall prevention function has caused stall Overload alarm prevention to be activated Switched high when stall prevention is 1 Permissible load 24VDC 0 1A Instantaneous power Switched low when instantaneous power failure or undervoltage protection is activated 7 Permissible load 24VDC 0 1A Switched low when the output frequency has reached or exceeded the detection frequency set as appropriate Switched high when FH Frequency detection below the detection 9 7 Permissible load 24VDC 0 1A Frequency setting current Input signals Analog frequency setting Contact Inverter running Output terminal function selection Pr 190 to Pr 195 change terminal functions Up to frequency Output signals Open collector output Common to the RUN SU OL IPF and FU terminals common Factory setting of output item For meter One selected from 16 monitoring Frequency items such as output frequency Permissible load current 1mA is output 2 1440 pulses second at 60Hz The output signal is proportional Factory setting of output item to the magnitude of each Frequency monitoring item Output signal 0 to 10VDC Permissible load current 1mA Analog signal output With the operation panel connector communication can be made through RS 485 Conforming Standard EIA Standard RS 485 PU connector Transmission format Multi drop link Communic
51. lf tone screened parameters allow their settings to be changed during operation if 0 factory setting has been set in Pr 77 Note that the Pr 72 and Pr 240 settings cannot be changed during external operation Can be set when Pr 80 81 9999 Pr 60 7 or 8 Can be accessed when Pr 80 81 9999 Pr 77 801 Can be accessed when Pr 270 1 or 3 Pr 80 81 9999 The setting range and min setting unit will differ according to the Pr 71 applied motor setting value 7 Can be accessed when Pr 29 3 8 Parameters marked asterisk on top are different setting range factory setting or function from FR A540L 9 Page numbers correspond to A540 A560L instruction manual 1B07401 0x Brake sequence functions Calibration functions Additional function oo 23 5 PROTECTIVE FUNCTIONS This chapter explains the protective functions of this product Always read the instructions before using the equipment 5 1 Errors Alarms OOO 5 2 Troubleshooting 111111111130 5 3 Precautions for Maintenance and Inspection 11134 OUTLINE INSTALLATION AND WIRING OPERATION PARAMETERS CHAPTER 5 Muster dat ts CHAPTER 6 SPECIFICATIONS APPENDICES 5 1 Errors Alarms PROTECTIVE FUNCTIONS If any fault has occurred in the inverter the corresponding protective function is activated and the error alarm indication appears automatically on the PU display When the protective
52. load current reduces to prevent the inverter from resulting in overcurrent shut off When the load current has reduced below 150 this function increases the frequency again to accelerate and operate the inverter up to the set frequency If a current not less than 150 Note 4 of the rated inverter current flows in the motor this function lowers the frequency until the load current reduces to prevent overcurrent shut off When the load current has reduced below 150 this function increases the frequency up to the set value Output side ground fault overcurrent protection External thermal relay operation Note 3 During acceleration During constant speed operation If the regenerative energy of the motor has increased above the brake capability this function increases the frequency to prevent overvoltage shut off If a current not less than 150 Note 4 of the rated inverter current flows in the motor this function increases the frequency until the load current reduces to prevent the inverter from resulting in overcurrent shut off When the load current has reduced below 150 this function decreases the frequency again Stops the inverter output if the dedicated inboard option used in the inverter results in setting error or connection connector fault When the high power factor converter connection is selected this alarm is displayed if AC power is connected to R S T During deceleration Option alarm Stops
53. ng manuals Name Description Power supply Earth leakage circuit breaker ELB or no fuse breaker NFB Magnetic contactor E ce Reactors AC reactor FASO MT BAL Inverter Ground Devices connected to the output Ground Use the power supply within the permissible power supply specifications of the inverter The breaker should be selected with care since a large inrush current flows in the inverter at power on The breaker must have overcurrent protection and earth leakage protection The magnetic contactor need not be provided When installed do not use it to start or stop the inverter It might reduce the inverter life The reactors must be used when the power factor is to be improved or the inverter is installed near a large power supply system ten times or more of Inverter Output and wiring distance within 10m 32 81 feet Make selection carefully The inverter life is influenced by ambient temperature The ambient temperature should be as low as possible within the permissible range This must be noted especially when the inverter is installed in an enclosure Incorrect wiring might lead to inverter damage The control signal lines must be kept fully away from the main circuit to protect them from noise Do not connect a power capacitor surge suppressor or radio noise filter to the output side To prevent an electric shock always ground the motor
54. ns Repair the output short circuit and ground fault Repair or replace the motor Lengthen the deceleration time Eliminate the sudden fluctuate in the load Lengthen the deceleration time Investigate the braking operation Repair the short circuited section Replace the cooling fan power supply Replace the fuse Repair the short circuited section and replace the DC fuse Repair the output short circuit and ground fault Repair or replace the motor Replace the cooling fan Clean the cooling fins Keep the ambient temperature within the specifications Repair the short circuited section Replace the control power supply board When the protective function is activated take proper corrective action reset the inverter then resume operation 31 PROTECTIVE FUNCTIONS 5 2 2 Faults and check points POINT Check the corresponding areas If the cause is still unknown it is recommended to initialize the parameters return to factory settings re set the required parameter values and check again 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 2 Check the input signals Check that the start signal is input Check that both the forward and reverse rotation start signals are not input Check that the frequency setting signal is not zero Check that the
55. nverter 15cm 5 91 inches 10cm 3 94 inches or more or more NNNNNNNNNNNNNNNNNNNNNNNNNNNN 20cm 7 87 inches or more 2 2 Wiring INSTALLATION AND WIRING 2 2 1 Terminal connection diagram Inverter FR A500L 3 phase AC power supply PU connector X Note 8 RS 485 Ground Note 1 24VDC power output and extemal transistor common Contact input common for source logic Brake Resistor Built See Page 49 Option Reverse rotation start amp oO O OSTR PR V Start self holding STOP Q i Brake Brake unit selection resistor 1 option High ORH option 530K 900K Forward rotation start Multi speed selection Middle amp o O ORM Max 15 speeds Error output Low o O ORL contact output Note 9 Jog mode QJOG Second acceleration deceleration time selection O ORT RUN 7 9 Running SU 12179 Up to frequency IPF Output stop O 0 0 MRS Reset 6 O 0 0 RES Instantaneous power failure Current input selection O O O AU M Open collector OL outputs 9 Overload Note 1 Note 4 FU 1 Frequency detection Selection of automatic restart O o ocs m instantaneous power ailure bed bed bed bet be
56. nverter power A continuous flow of large current could cause a fire Do not connect the resistor directly to the DC terminals P N This could cause a fire 3 Injury Prevention Apply only the voltage specified in the instruction manual to each terminal to prevent damage etc Ensure that the cables are connected to the correct terminals Otherwise damage etc may occur Always make sure that polarity is correct to prevent damage etc After the inverter has been operating for a relatively long period of time do not touch the inverter as it may be 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 When carrying products use correct lifting gear to prevent injury Ensure that installation position and material can withstand the weight of the inverter Install according to the information in the Instruction Manual Do not operate if the inverter is damaged or has parts missing Do not stand or rest heavy objects on the inverter Check the inverter mounting orientation is correct Prevent screws wire fragments conductive bodies oil or other flammable substances from entering the inverter Do not drop the inverter or subject it to impact Use the inverter under the following environmental conditions 10 C to 40 14 F to 104 F non freezin
57. o 5VDC factory setting 2 voltage and 0 to 10VDC from operation terminal Input resistance 10kQ Maximum permissible voltage 20V By entering 4 to 20mADC the maximum output frequency is reached at 20mA and I O 4 are proportional This input signal is valid only when the AU signal is on Input resistance 2500 Maximum permissible current 30mA By entering 0 to 5VDC 0 to 10 this signal is added to the frequency setting 4 Auxiliary frequency signal of terminal 2 or 4 Switch between input 0 to 5 and 0 to 10VDC factory setting setting from operation terminal Input resistance 10kQ Maximum permissible voltage 20V Frequency setting Common to the frequency setting signal terminal 2 1 or 4 and analog output terminal input common AM Do not earth Change over contact output indicating that the output has been stopped by the inverter protective function activated AQ BO C Alarm output 200VAC 0 3A 30VDC 0 3A Alarm discontinuity across B C continuity across A C normal continuity across B C discontinuity across A C 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 dynamic brake operation Permissible load 24VDC 0 1A Switched low when the output frequency has reached within 10 of the set frequency factory setting variable Switched high during acceleration deceleration or Permissib
58. on third frequency detection during program mode operation during PU operation overload alarm regenerative Operating status brake pre alarm electronic overcurrent protection pre alarm zero current detection output current detection PID lower limit PID upper limit PID forward reverse rotation commercial power supply inverter switch over MC1 2 3 operation ready brake release request fan fault and fin overheat pre alarm minor fault Open collector output Contact output change over contact 230VAC 0 3A 30VDC 0 3A Alarm inverter trip Open collector alarm code 4 bit output 1 signal can be selected from output frequency motor current steady or peak value output voltage frequency setting running speed motor torque converter output voltage steady or For meter peak value regenerative brake duty electronic overcurrent protection load factor input power output power load meter and motor exciting current Pulse train output 1440 pulses sec full scale and analog output 0 to 10VDC Output signals 42 SPECIFICATIONS Selection can be made from output frequency motor current steady or peak value output Display on voltage frequency setting running speed motor torque converter output voltage steady or operation panel 9 peak value electronic overcurrent protection load factor input power output power load FR DUO4 or meter motor exciting current cumulative energization
59. on selection 0 to 99 9999 0 9 9 9 94 9 9 Additional function 21 PARAMETERS Minimum Refer To Setting Range Setting Factory Setting Page umber Increments lt Note9 gt 200 Programmed operation minute second 0 to 3 1 131 selection 1 0 0 to 2 Rotation direction 0 to 400 9999 Frequency 0 1Hz 9999 131 0 to 99 59 Time Minute or second 0 0 to 2 Rotation direction 1 0 to 400 9999 Frequency 0 1Hz 0 to 99 59 Time Minute or second Program set 3 0 to 2 Rotation direction 1 21 to 30 0 to 400 9999 Frequency 0 1Hz 0 to 99 59 Time Minute or second 0 23 Tmerseimg oos O 0 Multi speed seting speed 15 Soft PWM setting 0 240 1 1 135 m iii add 12 42 t o es Stop selection 0 to 100 sec 9999 9999 Start holding time 0 to 10 sec 9999 9999 m Power failure stop selection 10700101 1 SESS Subtraction starting frequency 0 to 120Hz 9999 0 01Hz 60Hz lt 50Hz gt 137 7 0 to 3600 0 1 sec 0 to 3600 0 1 sec Power failure deceleration time 2 0 to 360 sec 9999 9999 Power failure deceleration time switch 0 to 400Hz 0 01Hz over frequency Program set 1 201 1 to 10 Program set 2 11 to 20 Programmed operation Sub functions Multi speed operation Stop selection function functions Power failure stop function 1 1 Selection function High speed frequency control Stop on contact exciting current low 0 to 1000 9999 1 9999 s
60. ower Large capacity motor started Check power system equipment such as power E UVT Jumper or DC reactor connected across terminals P supply P1 Connect jumper or DC reactor across terminals P P1 E FIN Ambient temperature too high Set ambient temperature within specifications E GF Check motor and cables for ground fault Resolve ground faults E OHT Check motor for overheat Reduce load and frequency of operation E OLT Motor used under overload Reduce 086 Increase motor and inverter capacities E OPT Check for loose connectors Connect securely 7 E OP1 to E OP3 Check the option function setting etc Control card E PUE Fit DU or PU securely E RET E LF Check for open output phase Repair open phase E CPU Check for loose connectors Connect securely E P24 Check PC terminal output for short Repair short E CTE Check PU connector cable for short Check PU and cable E MB1 to MB7 Check brake sequence STOP key of operation panel pressed during external Check load status PS operation to stop Refer to Pr 75 RB_ Brake resistor used too often Increase deceleration time Load too large Sudden acceleration Reduce load amount or frequency of running Motor used under overload Lighten load Sudden deceleration Reduce frequency of braking oL Overvoltage stall OL Overcurrent stall E 14 DC fuse Is the DC circuit short circuited Repair the short circuited section
61. peed multiplying factor Note 5 Stop on contact PWM carrier frequency 0 1 2 9999 1 9999 1 5 136 37 37 139 140 140 140 143 43 Stop on contact load torque high speed 270 frequency control selection EZE EZE 22 PARAMETERS Minimum Refer To Setting Range Setting Factory Setting Page umber Increments lt Note9 gt Brake opening frequency Note 3 0 to 30Hz 0 01Hz Brake opening current Note 3 0 to 200 130 280 Brake opening current detection time t2 sec 0 3 sec 442 Note 3 Brake operation time at start Note 3 282 Brake operation frequency Note 3 0 to 30Hz 0 01Hz EN 2 Brake operation time at stop Note 3 Deceleration detection function selection 142 Note 3 wesecser or EE 900 FfMtemmalcabrain 90i AMtemiecabr on 902 Frequency setting voltage bias 00010 ov omz 154 1 to 60Hz Frequency setting voltage gain 0 to 10V 400 gt 0 01 2 rae JE 904 Frequency setting current bias to 20mA 0 to 60Hz 0 01Hz 4mA 0 2 154 1 to 60Hz ESL Frequency setting current gain 0 to 20mA A00Hz 0 01Hz Parameter unit SS Refer to the unit instruction manual for details Note 1 Indicates the parameter settings which are ignored when the advanced magnetic flux vector control mode is selected 2 The ha
62. pply error capacitor overcurrent cooling fin overheat gate power supply error Refer to the next page page 27 for details Operation panel power short circuit Brake resistor overheat protection Main circuit error If Pr 195 A B C terminal function selection is as set in the factory The terminals used must be allocated using Pr 190 to Pr 195 External thermal relay operation is only activated when is set in any of Pr 180 to Pr 186 input terminal function selection Indicates that the stall prevention operation level has been set to 150 factory setting If this value is changed stall prevention is operated at the new value Resetting method When the protective function is activated and the inverter stops its output the motor is coasted to a stop the inverter is kept stopped Unless reset the inverter cannot restart To reset the inverter use any of the following methods switch power off once then on again short reset terminal RES SD for more than 0 1 seconds then open press the RESET key of the parameter unit use the help function of the parameter unit If RES SD is kept shorted the operation panel will show Err or the parameter unit will show that the inverter is being reset 26 PROTECTIVE FUNCTIONS Main circuit error E 15 details There are two 7 segment LEDs on the
63. quipment to the inverter output may damage the equipment The electronic overcurrent protection does not guarantee protection of the motor from overheat 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 harmonics from the inverter may heat damage the power capacitor and generator When an over 400V class motor is inverter driven it should be insulation enhanced or surge voltages suppressed Surge voltages attributable to the wiring constants may occur at motor terminals deteriorating the insulation of the motor When parameter clear or all clear is performed each parameter returns to the factory setting Re set the required parameters before starting operation 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 g mechanical brake to ensure safety Before running the inverter which had been stored for a long period always perform inspection and test operation 5 Emergency stop Provide a safety backup such as an emergency brake which will prevent the machine and equipment from hazardous conditions if the inverter fails 6 Maint
64. r and motor capacities in advanced magnetic flux vector control Check that the wiring length is within 30m in advanced magnetic flux vector control Check that the wiring length is correct in V F control 8 Operation mode is not changed properly If the operation mode is not changed properly check the following 1 External input signal I Check that the STF or STR signal is off When it is on the operation mode cannot be changed 2 Parameter setting I Check the 79 setting When the setting of Pr 79 operation mode selection is 0 factory setting switching input power on places the inverter in the external operation mode Press the operation panel s MODE key three times and press the UP key press the PU key for the parameter unit FR PU04 This changes the external operation mode into the PU operation mode For any other setting 1 to 8 the operation mode is limited according to the setting 9 Operation panel FR DU04 display is not provided Make sure that the operation panel is connected securely with the inverter 10 POWER lamp is not lit Make sure that the wiring and installation are correct 33 5 3 Precautions for Maintenance and Inspection PROTECTIVE FUNCTIONS The transistorized inverter is a static unit mainly consisting of semiconductor devices Daily inspection must be performed to prevent any fault from occurring due to adverse influence by the operating environmen
65. rent When using an external power supply for transistor output use terminal SD as a common to prevent misoperation caused by leakage current 4 How to use terminals STOP CS and 1 Using the STOP terminal A connection example for sink logic for self holding the start signal forward rotation reverse rotation is shown on the right 2 Using the CS terminal This terminal is used to perform automatic restart after instantaneous power failure and commercial power supply inverter switch over operation lt Example Automatic restart after instantaneous power failure in sink logic gt Connect terminals CS SD and set a value other than 9999 in Pr 57 coasting time for automatic restart after instantaneous power failure 3 Using the PC terminal This terminal can be used as 24VDC power output using SD as a common terminal Specifications 18V to 26VDC 0 1A permissible current Note that the wiring length should be within 30m Do not short terminals PC SD When terminal PC is used as a 24V power supply leakage current from transistor output cannot be prevented 15 Forward rotation Reverse rotation STOP MRS Stop RES 50 STF 1 o STR Short INSTALLATION AND WIRING 2 2 4 Connection to the PU connector 1 When connecting the operation
66. t o 50 i common f collector output common 1 Common to sink and source Control input signals no voltage input allowed Note 7 Note 1 e 10E 10V calibration resistor Meter 1 1 2W10kQ e q frequency meter 10 5V 1 7777 B Note 6 5 DCO 5V Selected o Moving coil Frequency setting potentiometer 1 2W1kQ Note 2 t 5 Analog common 5 9 fi Analog signal output Common DCO 10V DCO 1mA full scale Note 6 Auxiliary input 0 10 B29 229 Selected Current input gt 4 DC 4 20mA Note 8 _ Ground Frequency setting signals analog Main circuit terminal O Control circuit input terminal Control circuit output terminal Notes 1 This connection diagram shows the example for the sink logic factory 4 The output terminal can output the error alarm code and 26 types of set control circuit When using the source logic refer to page 14 for the functions can be independently assigned with Pr 190 to 195 connections 5 The input signal can be changed over with Pr 73 2 Use of the 2W1kQis recommended when the frequency setting is changed frequently 3 Always connect the enclosed DCL at P1 P 375 450K 7 Always ground the inverter unit DCL and motor DCL is prewired in the panel P1 terminal is not prepared as terminals 8
67. t such as temperature humidity dust dirt and vibration changes in the parts with time service life and other factors 5 3 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 switch power off When more than 10 minutes have elapsed make sure that the voltage across the main circuit terminals P N of the inverter is 30VDC or less using a tester etc 5 3 2 Check items 1 Daily inspections Check the following 1 Motor operation fault 2 Improper installation environment 3 Cooling system fault 4 Unusual vibration and noise 5 Unusual overheating and discoloration During operation check the inverter input voltages using a tester 2 Cleaning Always run the inverter in a clean state When cleaning the inverter gently wipe dirty areas with a soft cloth immersed in neutral detergent or ethanol Note Do not use solvent such as acetone benzene toluene and alcohol as they will cause the inverter surface paint to peel off Do not use detergent or alcohol to clean the display and other sections of the operation panel FR DU04 or parameter unit FR PU04 as these sections will deform 5 3 3 Periodic inspection Check the areas inaccessible during operation and requiring periodic inspection For periodic inspection consult us 1 Cooling system Clean the air filter et
68. tem Measuring Point Measuring Instrument Power supply voltage V4 Power supply side power Pi factor Pf x 100 1 Pf Bvil u x Difference between phases is within 1 of maximum output voltage Current should be equal to or less than rated inverter current Difference between phases is 10 or lower P2 W21 W22 2 wattmeter method or 3 wattmeter method Rectifier type AC voltmeter Output side voltage V2 Across U V V Wand W U Note 1 Not moving iron type Output side current l2 U V and W line currents Moving iron type AC ammeter At U V and W and across U V Electrodynamic type single Output side power P2 and V W phase wattmeter 1 Calculate in similar manner to power supply side power factor Output side power factor 100 2 43 v20 12 POWER lamp lit Moving coil type such as 1 35 x V1 tester Maximum 760V during regenerative operation Across 2 0 to 5V 0 to 10VDC Frequency setting signal Across 1 0 to 5V 0 to 10VDC Across 4 4 to 20mADC Across 10 5 5VDC supply Across 10E 5 10VDC Approximately 5VDC at maximum frequency without frequency meter T1 Converter output Across P N lt Across and gt common Across FM SD Moving coil type Tester etc may be used Internal Frequency meter signal resistance 50 or larger Pulse width T1 Adjusted by Pr 900 Pulse cycle T2 Set by Pr 55 Valid for frequency monitoring
69. the inverter output if a functional fault such as communication error of the communication option occurs in the inboard option loaded in any slot Option slot alarm Stops the output if a fault occurs in E PROM which stores parameter settings This function stops the inverter output if communication between inverter and PU is suspended e g the operation panel or parameter unit is disconnected when 2 3 16 or 17 is set in Pr 75 reset selection PU disconnection detection PU stop selection This function stops the inverter output if the number of successive communication errors is greater than the number of permissible retries when Pr 121 value is 9999 for RS 485 communication from PU connector This function stops the inverter output if communication is broken for a period of time set in Pr 122 PU disconnection occurrence RET Retry No Retry count exceeded If operation cannot be resumed within the number of retries set this Over function stops the inverter output ELF Open output phase i i i protection W on the inverter s output side load side opens E CPU CPU Fault This function stops the inverter output when any of the three phases U If the arithmetic operation of the built in CPU does not end within a predetermined period the inverter self determines it has an alarm and stops the output When 24VDC power output from the PC terminal is shorted this function shuts off the power output At this
70. time actual operation time watt hour parameter unit meter regenerative brake duty and motor load factor FR PU04 Alarm Alarm definition is displayed when protective function is activated 8 alarm definitions are stored definition Four alarm definitions are only displayed on the operation panel Operating Input terminal signal states output terminal signal states option fitting status terminal Additional status assignment status display on parameter unit Alarm Output voltage current frequency cumulative energization time FR PUO4 definition immediately before protective function is activated only Interactive Operation guide and troubleshooting by help function Overcurrent shut off during acceleration deceleration constant speed regenerative overvoltage shut off undervoltage instantaneous power failure overload shut off electronic overcurrent protection ground fault overcurrent stall prevention overload warning fin Protective alarm functions overheat option error parameter error PU disconnection No of retries over output open phase CPU error 24VDC power supply output short circuit operation panel power supply short circuit main circuit error 90 RH or less non condensing Max 1000m 3280 80 feet above sea level 5 9m s 0 6G or less conforms to JIS C 0911 Environment Note 1 For FR A540L 375K 450K at constant torque CT rating maximum ambient temperature can be 50 C 122 F
71. time all external contact inputs switch off The inverter cannot be reset by entering the RES signal To reset use the operation panel or switch power off then on again CPU error 24VDC power output short circuit 25 PROTECTIVE FUNCTIONS Operation Panel Display FR DU04 Parameter Unit Description FR PU04 When the operation panel power P5S of the PU connector is shorted this function shuts off the power output At this time the operation panel parameter unit cannot be used and RS 485 communication from the PU connector cannot be made To reset enter the RES signal or switch power off then on again Inverters of 7 5K or less contains a brake resistor When the regenerative brake duty from the motor has reached 85 of the specified value pre alarm RB indication occurs If the specified value is exceeded the brake circuit operation is stopped temporarily to protect the brake resistor from overheating If the brake is operated in this state regenerative overvoltage shut off will occur When the brake resistor has cooled the brake operation is resumed 1 to seduence ifor This function stops the inverter output if a sequence error occurs during MB7 the use of the brake sequence function Pr 278 to Pr 285 DC fuse blown The inverter output will stop if the DC fuse blows Brake unit cooling fin overheat control board ambient temperature error output overcurrent cooling fan power su
72. tions detection Additional 126 User group read selection 0 1 10 11 1 2 5 Automatic restart after instantaneous 1 5 power failure selection oO 3 First cushion time for restart 0 to 20 sec 0 2 558 z First cushion voltage for restart 0 to 100 2 165 Restart stall prevention operation level 0 to 150 0 1 150 125 Watt hour meter clear Actual operation hour meter clear User group 1 registration 0 to 999 174 User group 1 deletion 0 to 999 9999 User group 2 registration 0 to 999 User group 2 deletion 0 to 999 9999 180 RL terminal function selection 0 to 99 9999 RM terminal function selection 0 to 99 9999 1 3 User functions RH terminal function selection 0 to 99 9999 1 1 1 1 1 9 19 SU terminal function selection 0 to 199 9999 192 IPF terminal function selection 0 to 199 9999 CS terminal function selection 0 to 99 9999 RUN terminal function selection 0 to 199 9999 2 i i 1 OL terminal function selection 0 to 199 9999 5 JOG terminal function selection Already Assigned Terminal assignment functions 1 1 FU terminal function selection 0 to 199 9999 A B C terminal function selection 0 to 199 9999 User s initial value setting 0 to 999 9999 1 130 Pr 185 This terminal is already assigned in Factory User can not use 7 74 7 7 8 8 8 RT terminal function selection 0 to 99 9999 84 AU terminal functi
73. tor Cooling fin overheat eae output will stop if the cooling fin s temperature rises above the specified Gate power supply error output will stop if the gate power supply voltage drops below the specified 27 PROTECTIVE FUNCTIONS To know the operating status at the occurrence of alarm When any alarm has occurred the display automatically switches to the indication of the corresponding protective function error By pressing the MODE key 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 However these values are not stored in memory and are erased when the inverter is reset 5 1 2 Correspondences between digital and actual characters There are the following correspondences between the actual alphanumeric characters and the digital characters displayed on the operation panel tua Ba 0 4 UU 411 11 21 2 Nn a Un Wt sot iy au B s J E Es s pr a a SAO EN CS DEUS CUBES S ES COC ye ey 28 PROTECTIVE FUNCTIONS 5 1 3 Alarm code output By setting Pr 76 alarm code output selection an alarm definition can be output as a 4 bit digital signal This signal is output from the open
74. trol circuit terminal block and fix it with the mounting screws Make sure that the control circuit connector is fitted correctly While power is on never disconnect the control circuit terminal block The sink source logic change over connector must be fitted in only one of those positions If it is fitted in both positions at the same time the inverter may be damaged 13 INSTALLATION AND WIRING 4 Sink logic type In this logic a signal switches on when a current flows out of the corresponding signal input terminal Terminal SD is common to the contact input signals Terminal SE is common to the open collector output signals Current 228232 8 STFE 3 O STR O il SD When using an external power supply for transistor output use terminal as common to prevent misoperation caused by leakage current Do not connect terminal SD of the inverter with terminal OV of the external power supply AY40 typ pe 1 Inverter transistor a module i T DC24V SD 4 RM 5 0 RL 14 INSTALLATION AND WIRING 5 Source logic type In this logic a signal switches on when a current flows into the corresponding signal input terminal Terminal PC is common to the contact input signals Terminal SE is common to the open collector output signals Cur
75. type etc If all measured values are almost the same the modules are without fault Module device numbers and terminals to be checked Tester DO T Measured Tester E NE EN Measured Value cii 2 Benin nu RA E 2 pers erem So Deci m pers Bem m LU erem Tee LU Continuity Lee u Nes mw Lee pene me B Pees v Continuity Sei uw LW PS me _ _ Fee ow p 5 Converter module Inverter module Converter module Per nverter module 37 PROTECTIVE FUNCTIONS 5 3 6 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 failure of the inverter For preventive maintenance the parts must be changed periodically 1 Cooling fan The cooling fan cools heat generating parts such as the main circuit semiconductor devices The life of the cooling fan bearing is usually 10 000 to 35 000 hours Hence the cooling fan must be changed 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 changed immediately 2 Smoothing capacitors A large capacity aluminum electrolyti
76. uced during constant speed operation When 85 of the preset value is reached pre alarm TH indication occurs When the specified value is reached the protective circuit is activated to stop the inverter output When a special motor such as a multi pole motor or more than one motor is run the motor cannot be protected by the electronic overcurrent protection Provide a thermal relay in the inverter output circuit If current not less than 150 of the rated output current flows and overcurrent shut off OC does not occur 20096 or less inverse time characteristics cause the electronic overcurrent protection to be activated to stop the inverter output Overload immunity 15096 60 sec At low speed regions the operation time may be short If a power failure has occurred in excess of 15msec this applies also to inverter input shut off this function is activated to stop the inverter output to prevent the control circuit from misoperation At this time the alarm output contacts are opened across B C and closed across A C Note 1 If a power failure persists for more than 100ms the alarm output is not provided and if the start signal is on at the time of power restoration the inverter will restart If a power failure is instantaneous within 15msec the control circuit operates properly If the inverter power supply voltage drops the control circuit will not operate properly Furthermore the motor torque could drop and the he
77. used Frequency setting signal Digital input Forward and reverse rotation start signal automatic self holding input 3 wire input can be Start signal selected Up to 15 speeds be selected Each speed can be selected in the range of 0 to 400Hz The Multi speed selection operation speed can be changed from the operation panel or parameter unit during operation Second third acceleration 0 to 3600 sec up to three different accelerations and decelerations deceleration time can be set individually selection Input signals Current input selection Input of frequency setting signal 4 to 20mADC terminal 4 is selected Output stop Instantaneous shut off of inverter output frequency voltage Alarm reset Alarm retained at the activation of protective function is reset Maximum minimum frequency setting frequency jump operation external thermal relay input selection polarity reversible operation automatic restart operation after instantaneous power Operation functions failure commercial power supply inverter switch over operation forward reverse rotation prevention slip compensation operation mode selection offline auto tuning function online auto tuning function PID control programmed operation computer link operation RS 485 5 different signals can be selected from inverter running up to frequency instantaneous power failure undervoltage frequency detection second frequency detecti

Mitsubishi Electronics FR-A500L User's Manual

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