Mitsubishi FR s500
FR - S 500 TRANSISTORIZED INVERTER IN S T R U C T IO N M A N U A L (D e ta ile d ) Chapter 3 Chapter 2 Chapter 4 FUNCTIONS Chapter 1 W IRING FUNCTIONS SPECIFICATIONS PROTECTIVE HEAD OFFICE:MITSUBISHI DENKI BLDG M ARUNOUCHI TOKYO 100-8310 Printed in Japan A-1 Thank you for choosing this Mitsubishi Transistorized inverter. This instruction manual (detailed) provides instructions for advanced use of the FR-S500 series inverters. Incorrect handling might cause an unexpected fault. Before using the inverter, always read this instruction manual and the instruction manual (basic) [IB-0600026] packed with the product carefully to use the equipment to its optimum. This instruction manual uses the International System of Units (SI). The measuring units in the yard and pound system are indicated in parentheses as reference values. This section is specifically about safety matters Do not attempt to install, operate, maintain or inspect the inverter until you have read through the instruction manual (basic) and appended documents carefully and can use the equipment correctly. Do not use the inverter until you have a full knowledge of the equipment, safety information and instructions. In this instruction manual, the safety instruction levels are classified into "WARNING" and "CAUTION". WARNING Assumes that incorrect handling may cause hazardous conditions, resulting in death or severe injury. CAUTION Assumes that incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause physical damage only. Note that even the CAUTION level may lead to a serious consequence according to conditions. Please follow the instructions of both levels because they are important to personnel safety. 1. Electric Shock Prevention WARNING While power is on or when the inverter is running, do not open the front cover. You may get an electric shock. Do not run the inverter with the front cover removed. Otherwise, you may access the exposed high-voltage terminals or the charging part of the circuitry and get an electric shock. If power is off, do not remove the front cover except for wiring or periodic inspection. You may access the charged inverter circuits and get an electric shock. Before starting wiring or inspection, check for residual voltages with a meter etc. more than 10 minutes after power-off. Earth the inverter. Any person who is involved in wiring or inspection of this equipment should be fully competent to do the work. Always install the inverter before wiring. Otherwise, you may get an electric shock or be injured. Perform setting dial and key operations with dry hands to prevent an electric shock. Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Otherwise, you may get an electric shock. Do not change the cooling fan while power is on. It is dangerous to change the cooling fan while power is on. When you have removed the front cover, do not touch the connector above the 3-digit monitor LED display. You will get an electric shock. A-2 2. Fire Prevention CAUTION Mount the inverter to incombustible material. Mounting it to or near combustible material can cause a fire. If the inverter has become faulty, switch off the inverter power. A continuous flow of large current could cause a fire. Do not connect a resistor directly to the DC terminals P(+), N(−). This could cause a fire. 3. Injury Prevention CAUTION Apply only the voltage specified in the instruction manual to each terminal to prevent damage etc. 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. While power is on and for some time after power-off, do not touch the inverter or brake resistor as they are hot and you may get burnt. 4. Additional instructions Also note the following points to prevent an accidental failure, injury, electric shock, etc. (1) Transportation and installation CAUTION When carrying products, use correct lifting gear to prevent injury. Do not stack the inverter boxes higher than the number recommended. Ensure that installation position and material can withstand the weight of the inverter. Install according to the information in the Instruction Manual. Do not operate if the inverter is damaged or has parts missing. When carrying the inverter, do not hold it by the front cover or setting dial; it may fall off or fail. Do not stand or rest heavy objects on the inverter. Check the inverter mounting orientation is correct. Prevent screws, wire fragments, other 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: Ambient temperature -10°C to +50°C (14°F to 122°F) (non-freezing) Ambient humidity 90%RH or less (non-condensing) Storage temperature -20°C to +65°C * (-4°F to 149°F) Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt) Environment Altitude, vibration Maximum 1000m (3280.80feet) above sea level for standard operation. After that derate by 3% for every extra 500m (1640.40feet) up to 2500m (8202.00feet) (91%). 5.9m/s 2 or less (conforming to JIS C 0040) *Temperatures applicable for a short time, e.g. in transit. A-3 (2) Wiring CAUTION Do not fit capacitive equipment such as power factor correction capacitor, radio 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 CAUTION Check all parameters, and ensure that the machine will not be damaged by a sudden start-up. When the load GD 2 is small (at the motor GD 2 or smaller) for 400V from 1.5K to 3.7K, the output current may vary when the output frequency is in the 20Hz to 30Hz range. If this is a problem, set the Pr. 72 "PWM frecuency selection" to 6kHz or higher. When setting the PWM to a higher frequency, check for noise or leakage current problem and take countermeasures against it. (4) Operation WARNING When you have chosen the retry function, stay away from the equipment as it will restart suddenly after an alarm stop. The [STOP] key is valid only when the appropriate function setting has been made. Prepare an emergency stop switch separately. Make sure that the start signal is off before resetting the inverter alarm. A failure to do so may restart the motor suddenly. The load used should be a three-phase induction motor only. Connection of any other electrical equipment to the inverter output may damage the equipment. Do not modify the equipment. CAUTION The electronic overcurrent protection does not guarantee protection of the motor from overheating. Do not use a magnetic contactor on the inverter input for frequent starting/stopping of the inverter. Use a noise filter to reduce the effect of electromagnetic interference. Otherwise nearby electronic equipment may be affected. Take measures to suppress harmonics. Otherwise power harmonics from the inverter may heat/damage the power capacitor and generator. When a 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 the 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 to ensure safety. Before running an inverter which had been stored for a long period, always perform inspection and test operation. A-4 (6) Maintenance, inspection and parts replacement CAUTION Do not carry out a megger (insulation resistance) test on the control circuit of the inverter. (7) Disposing of the inverter CAUTION Treat as industrial waste. (8) General instructions Many of the diagrams and drawings in this instruction manual show the inverter without a cover, or partially open. Never operate the inverter like this. Always replace the cover and follow this instruction manual when operating the inverter. I CONTENTS 1. WIRING 1 1.1 Japanese Version 2 1.1.1 Terminal connection diagram 2 1.1.2 Layout and wiring of main circuit terminals 3 1.2 North America Version 4 1.2.1 Terminal connection diagram 4 1.2.2 Layout and wiring of main circuit terminals 5 1.3 European Version 7 1.3.1 Terminal connection diagram 7 1.3.2 Layout and wiring of main circuit terminals 8 1.4 Description of I/O Terminal Specifications 9 1.4.1 Main circuit 9 1.4.2 Control circuit 9 1.5 How to Use the Main Circuit Terminals 11 1.5.1 Cables, wiring lengths, crimping terminals, etc. 11 1.5.2 Wiring instructions 12 1.5.3 Peripheral devices 13 1.5.4 Leakage current and installation of earth leakage circuit breaker 15 1.5.5 Power-off and magnetic contactor (MC) 17 1.5.6 Regarding the installation of the power factor improving reactor 18 1.5.7 Regarding noise and the installation of a noise filter 18 1.5.8 Grounding precautions 19 1.5.9 Regarding power harmonics 20 1.5.10 Japanese power harmonic suppression guideline 20 1.6 How to Use the Control Circuit Terminals 24 1.6.1 Terminal block layout 24 1.6.2 Wiring instructions 24 1.6.3 Changing the control logic 25 1.7 Input Terminals 28 1.7.1 Run (start) and stop (STF, STR, STOP) 28 1.7.2 Connection of frequency setting potentiometer and output frequency meter (10, 2, 5, 4, AU) 31 1.7.3 External frequency selection (REX, RH, RM, RL) 32 1.7.4 Indicator connection and adjustment 34 1.7.5 Control circuit common terminals (SD, 5, SE) 37 1.7.6 Signal inputs by contactless switches 37 1.8 How to Use the Input Signals (Assigned Terminals RL, RM, RH, STR) 38 1.8.1 Multi-speed setting (RL, RM, RH, REX signals): Setting "0, 1, 2, 8" Remote setting (RL, RM, RH signals): Setting "0, 1, 2" 38 1.8.2 Second function selection (RT signal): Setting "3" 38 Contents II 1.8.3 Current input selection "AU signal": Setting "4" 38 1.8.4 Start self-holding selection (STOP signal): Setting "5" 38 1.8.5 Output shut-off (MRS signal): Setting "6" 39 1.8.6 External thermal relay input: Setting "7" 39 1.8.7 Jog operation (JOG signal): Setting "9" 40 1.8.8 Reset signal: Setting "10" 40 1.8.9 PID control valid terminal: Setting "14" 41 1.8.10 PU operation/external operation switching: Setting "16" 41 1.9 Handling of the RS-485 Connector (Type with RS-485 Communication Function) 41 1.10 Design Information 44 2. FUNCTIONS 45 2.1 Function (Parameter) List 46 2.2 List of Parameters Classified by Purpose of Use 56 2.3 Explanation of Functions (Parameters) 58 2.3.1 Torque boost 58 2.3.2 Maximum and minimum frequency 59 2.3.3 Base frequency, Base frequency voltage 59 2.3.4 Multi-speed operation to to 61 2.3.5 Acceleration/deceleration time 62 2.3.6 Electronic overcurrent protection 64 2.3.7 DC injection brake 64 2.3.8 Starting frequency 65 2.3.9 Load pattern selection 66 2.3.10 Jog frequency 67 2.3.11 RUN key rotation direction selection 67 2.3.12 Stall prevention function and current limit function 68 2.3.13 Stall prevention 69 2.3.14 Acceleration/deceleration pattern 71 2.3.15 Extended function display selection 72 2.3.16 Frequency jump to 72 2.3.17 Speed display 73 2.3.18 Biases and gains of the frequency setting voltage (current) to 74 2.3.19 Start-time ground fault detection selection 78 2.4 Output Terminal Function Parameters 78 2.4.1 Up-to-frequency sensitivity 78 2.4.2 Output frequency detection 79 2.5 Current Detection Function Parameters 80 2.5.1 Output current detection functions 80 2.5.2 Zero current detection 81 2.6 Display Function Parameters 82 2.6.1 Monitor display 82 III 2.6.2 Setting dial function selection 83 2.6.3 Monitoring reference 84 2.7 Restart Operation Parameters 84 2.7.1 Restart setting 84 2.8 Additional Function Parameters 86 2.8.1 Remote setting function selection 86 2.9 Terminal Function Selection Parameters 88 2.9.1 Input terminal function selection 88 2.9.2 Output terminal function selection 90 2.10 Operation Selection Function Parameters 91 2.10.1 Retry function 91 2.10.2 PWM carrier frequency 92 2.10.3 Applied motor 93 2.10.4 Voltage input selection 93 2.10.5 Input filter time constant 94 2.10.6 Reset selection/PU stop selection 94 2.10.7 Cooling fan operation selection 96 2.10.8 Parameter write inhibit selection 97 2.10.9 Reverse rotation prevention selection 98 2.10.10 Operation mode selection 98 2.10.11 PID control to 101 2.11 Auxiliary Function Parameters 109 2.11.1 Slip compensation 109 2.11.2 Automatic torque boost selection 109 2.11.3 Motor primary resistance 111 2.12 Calibration Parameters 111 2.12.1 Meter (frequency meter) calibration (Japanese version) 111 2.12.2 Meter (frequency meter) calibration (NA and EC version) 113 2.13 Clear Parameters 115 2.13.1 Parameter clear 115 2.13.2 Alarm history clear 115 2.14 Communication Parameters (Only for the type having the RS-485 communication function) 116 2.14.1 Communication settings to , 118 2.14.2 Operation and speed command write 130 2.14.3 Link start mode selection 131 2.14.4 E 2 PROM write selection 132 2.15 Parameter Unit (FR-PU04) Setting 133 2.15.1 Parameter unit display language switching 133 2.15.2 Buzzer sound control 133 2.15.3 PU contrast adjustment 134 2.15.4 PU main display screen data selection 134 2.15.5 PU disconnection detection/PU setting lock 135 Contents IV 3. PROTECTIVE FUNCTIONS 136 3.1 Errors (Alarms) 137 3.1.1 Error (alarm) definitions 137 3.1.2 To know the operating status at the occurrence of alarm (Only when FR-PU04 is used) 145 3.1.3 Correspondence between digital and actual characters 145 3.1.4 Resetting the inverter 145 3.2 Troubleshooting 146 3.2.1 Motor remains stopped 146 3.2.2 Motor rotates in opposite direction 147 3.2.3 Speed greatly differs from the setting 147 3.2.4 Acceleration/deceleration is not smooth 147 3.2.5 Motor current is large 147 3.2.6 Speed does not increase 147 3.2.7 Speed varies during operation 147 3.2.8 Operation mode is not changed properly 148 3.2.9 Operation panel display is not operating 148 3.2.10 Parameter write cannot be performed 148 3.2.11 Motor produces annoying sound 148 3.3 Precautions for Maintenance and Inspection 149 3.3.1 Precautions for maintenance and inspection 149 3.3.2 Check items 149 3.3.3 Periodic inspection 149 3.3.4 Insulation resistance test using megger 150 3.3.5 Pressure test 150 3.3.6 Daily and periodic inspection 150 3.3.7 Replacement of parts 154 3.3.8 Measurement of main circuit voltages, currents and powers 157 4. SPECIFICATIONS 160 4.1 Specification List 161 4.1.1 Ratings 161 4.1.2 Common specifications 165 4.2 Outline Drawings 167 5. INSTRUCTIONS 170 5.1 Selecting Instructions 171 5.2 Peripheral Selecting Instructions 171 5.3 Operating Instructions 173 5.4 Inverter-driven 400V class motor 175 APPENDIX 176 APPENDIX 1 PARAMETER DATA CODE LIST 177 1 1 This chapter explains the basic "wiring" for use of this product. Always read the instructions before use. For description of "installation", refer to the instruction manual (basic). 1.1 Japanese Version 2 1.2 North America Version 4 1.3 European Version 7 1.4 Description of I/O Terminal specification 9 1.5 How to Use the Main Circuit Terminals 11 1.6 How to Use the Control Circuit Terminals 24 1.7 Input Terminals 28 1.8 How to Use the Input Signals (Assigned Terminals RL, RM, RH, STR) 38 1.9 Handling of the RS-485 Connector (Type with RS-485 Communication Function) 41 1.10 Design Information 44 <Abbreviations> PU Control panel and parameter unit (FR-PU04) Inverter Mitsubishi transistorized inverter FR-S 500 series FR-S500 Mitsubishi transistorized inverter FR-S 500 series Pr. Parameter number 1. WIRING Chapter 1 Chapter 2 Chapter 3 Chapter 4 [...]... 17) page 18) page 18) FR- BAL-0.4K FR- BEL-0.4K S-N10 2 2 (*3) (*3) FR- BAL-0.4K FR- BEL-0.4K S-N10 2 2 (*3) (*3) S-N10 FR- BAL-0.4K FR- BEL-0.4K FR- BAL0.75K FR- BEL0.75K 2 2 2 2 30AF/10A S-N10 30AF/15A S-N10 FR- BAL-1.5K FR- BEL-1.5K 2 2 30AF/20A S-N11, S-N12 FR- BAL-2.2K FR- BEL-2.2K 2 2 30AF/30A S-N20 FR- BAL-3.7K FR- BAL-3.7K 3.5 3.5 2) FR- S540-0.4K to 3.7K (-R) FR- S540-0.4K to 3.7K-NA (R) FR- S540-0.4K to 3.7K-EC... 30AF/5A S-N10 FR- BAL-0.4K FR- BEL-0.4K 2 2 30AF/10A S-N10 FR- BAL-0.4K FR- BEL-0.4K 2 2 30AF/10A S-N20 2 2 30AF/15A S-N20 FR- BAL-1.5K FR- BEL-1.5K 2 2 30AF/20A S-N21 FR- BAL-2.2K FR- BEL-2.2K 2 2 FR- BAL0.75K FR- BEL0.75K 4) FR- S510W-0.1K to 0.75K (-R) FR- S510W-0.1K to 0.75K-NA Motor Output (kW (HP)) Inverter Model 0.1 (1/8) 0.2 (1/4) 0.4 (1/2) 0.75 (1) FR- S510W0.1K FR- S510W0.2K FR- S510W0.4K FR- S510W0.75K... H0.4K H0.4K FR- BALFR-BEL2 2 S-N10 H0.75K H0.75K FR- BALFR-BEL2 2 S-N10 H1.5K H1.5K FR- BALFR-BELS-N20 2 2 H2.2K H2.2K FR- BALFR-BALS-N20 2 2 H3.7K H3.7K 13 1 3) FR- S520S-0.1K to 1.5K (-R) FR- S520S-0.2K to 1.5K-EC (R) Motor Output (kW (HP)) 0.1 (1/8) 0.2 (1/4) 0.4 (1/2) 0.75 (1) 1.5 (2) Inverter Model FR- S520S0.1K FR- S520S0.2K FR- S520S0.4K FR- S520S0.75K FR- S520S1.5K Rated current of Circuit Breaker (Refer... the capacity Refer to the following list and prepare appropriate peripheral devices: 1) FR- S520-0.1K to 3.7K (-R) (-C) FR- S520-0.1K to 3.7K-NA Motor Output (kW (HP)) 0.1 (1/8) 0.2 (1/4) 0.4 (1/2) 0.75 (1) 1.5 (2) 2.2 (3) 3.7 (5) Inverter Model FR- S5200.1K FR- S5200.2K FR- S5200.4K FR- S5200.75K FR- S5201.5K FR- S5202.2K FR- S5203.7K Rated current of Circuit Breaker (Refer to page 15) (*1) 30AF/5A 30AF/5A 30AF/5A... Model FR- S5400.4K FR- S5400.75K FR- S5401.5K FR- S5402.2K FR- S5403.7K Rated current of Circuit Breaker (Refer to page 15) (*1) 30AF/5A 30AF/5A 30AF/10A 30AF/15A 30AF/20A Power Power Cables (mm2) Magnetic Factor Factor (*2) Contactor Improving Improving (MC) R, S, T AC Reactor DC Reactor (Refer to page 18) page 18) FR- BALFR-BELS-N10 2 2 H0.4K H0.4K FR- BALFR-BEL2... terminals FR- S520-1.5K, 2.2K, 3.7K (-R) (-C) FR- S520-0.1K, 0.2K, 0.4K, 0.75K (-R) (-C) FR- S540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K (-R) Jumper Jumper N N P1 P U V P W P1 R R S T S T U V W IM IM Power supply Power supply Motor FR- S520S-0.1K, 0.2K, 0.4K, 0.75K (-R) FR- S520S-1.5K (-R) Jumper Jumper N N P1 P U V P W P1 R R S Motor S U V W IM IM Power supply Power supply Motor FR- S510W-0.1K, 0.2K, 0.4K (-R) N R S U FR- S510W-0.75K... appropriate measures, e.g set the carrier frequency in Pr 72 to a low value, use an earth leakage circuit breaker designed for suppression of harmonics and surges, and use the electronic overcurrent protection built in the inverter 18 Noise reduction examples Install filter Control box FR- BLF FR- BSF01 Reduce carrier frequency Install filter on inverter's input side FR- BLF FR- BSF01 on inverter's output side... wiring lengths, crimping terminals, etc The following selection example assumes the wiring length of 20m (65.62feet) 1) FR- S520-0.1K to 3.7K (-R) (-C) FR- S520-0.1K to 3.7K-NA Applicable Terminal Tightening Screw Inverter Torque Size Model Nm FR- S520-0.1K to 0.75K FR- S5201.5K, 2.2K FR- S520-3.7K PVC Insulated Cables AWG mm2 mm2 R, S, T U, V, W R, S, T U, V, W R, S, T U, V, W R, S, T U, V, W Cables Crimping... 12 4 2.5 2) FR- S540-0.4K to 3.7K (-R) FR- S540-0.4K to 3.7K-NA (R) FR- S540-0.4K to 3.7K-EC (R) PVC Insulated Cables Applicable Terminal Tightening Screw Inverter Torque AWG mm2 mm2 Size Model Nm R, S, T R, S, T R, S, T R, S, T FR- S540-0.4K M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5 to 3.7K Crimping Terminals Cables 3) FR- S520S-0.1K... to 1.5K (-R) FR- S520S-0.2K to 1.5K-EC (R) PVC Insulated Applicable Terminal Tightening Cables Screw Inverter Torque AWG mm2 mm2 Size Model Nm R, S R, S R, S R, S U, V, W U, V, W U, V, W U, V, W FR- S520SM3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5 0.1K to 0.75K FR- S520SM4 1.5 2-4 2-4 2 2 14 14 2.5 2.5 1.5K Crimping Terminals Cables 4) FR- S510W-0.1K to 0.75K (-R) FR- S510W-0.1K . 44 <Abbreviations> PU Control panel and parameter unit (FR-PU04) Inverter Mitsubishi transistorized inverter FR-S 500 series FR-S500 Mitsubishi transistorized inverter FR-S 500 series Pr. Parameter. IRING FUNCTIONS SPECIFICATIONS PROTECTIVE HEAD OFFICE :MITSUBISHI DENKI BLDG M ARUNOUCHI TOKYO 100-8310 Printed in Japan A-1 Thank you for choosing this Mitsubishi Transistorized inverter. This instruction. Transistorized inverter. This instruction manual (detailed) provides instructions for advanced use of the FR-S500 series inverters. Incorrect handling might cause an unexpected fault. Before using the inverter,