Mitsubishi Electric FR-S500E Bedienungsanleitung

FR-S500E

Frequency Inverter

Instruction Manual

(Detailed)

FR-S520SE-0.2K to 1.5K-EC,

FR-S540E-0.4K – 3.7K-EC

INDUSTRIAL AUTOMATION

MIT

HI ELE

TRI

MIT

HI ELE

TRI

Art. no.: 160474

01 09 2004

IB(NA)-0600211ENG

Version A

A-1

1. Electric Shock Prevention

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-0600210ENG]

packed with the product carefully to use the equipment to its optimum.

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have read

through this instruction manual (basic) and appended documents carefully and can

use the equipment correctly. Do not use the inverter until you have a full knowledge

of the equipment, safety information and instructions.

In this instruction manual (detailed), the safety instruction levels are classified into

"WARNING" and "CAUTION".

Assumes that incorrect handling may cause hazardous

conditions, resulting in death or severe injury.

Assumes that incorrect handling may cause hazardous

conditions, resulting in medium or slight injury, or may cause

physical damage only.

Note that even the level may lead to a serious consequence

according to conditions. Please follow the instructions of both levels because they are

important to personnel safety.

WARNING

While power is on or when the inverter is running, do not open the front cover. You

may get an electric shock.

Do not run the inverter with the front cover or wiring cover removed. Otherwise,

you may access the exposed high-voltage terminals or the charging part of the

circuitry and get an electric shock. Also, the inverter's ability to withstand

earthquakes will deteriorate.

Even if power is off, do not remove the front cover except for wiring or periodic

inspection. You may access the charged inverter circuits and get an electric shock.

Before starting wiring or inspection, check to make sure that the 3-digit LED inverter

monitor is off, wait for at least 10 minutes after the power supply has been switched

off, and check to make sure that there are no residual voltage using a tester or the

like.

This inverter must be earthed. Earthing must conform to the requirements of

national and local safety regulations and electrical codes. (JIS, NEC section 250,

IEC 536 class 1 and other applicable standards)

Any person who is involved in the wiring or inspection of this equipment should be

fully competent to do the work.

Always install the inverter before wiring. Otherwise, you may get an electric shock

or be injured.

Perform setting dial and key operations with dry hands to prevent an electric

shock.

Do not subject the cables to scratches, excessive stress, heavy loads or pinching.

Otherwise, you may get an electric shock.

Do not change the cooling fan while power is on. It is dangerous to change the

cooling fan while power is on.

When you have removed the front cover, do not touch the connector above the 3-

digit monitor LED display. Otherwise, you get an electrick shock.

WARNING

CAUTION

A-2

2. Fire Prevention

3. Injury Prevention

4. Additional Instructions

Also note the following points to prevent an accidental failure, injury, electric shock,

etc.

(1) Transportation and installation

CAUTION

Mount the inverter on an incombustible surface. Installing the inverter directly on or near

a combustible surface could lead to a fire.

If the inverter has become faulty, switch off the inverter power. A continuous flow of

large current could cause a fire.

Do not connect a resistor directly to the DC terminals +,

. This could cause a fire.

CAUTION

Apply only the voltage specified in the instruction manual to each terminal to

prevent damage, etc.

Always connect to the correct terminal to prevent damage, etc.

Always make sure that polarity is correct to prevent damage, etc.

While power is on or for some time after power-off, do not touch the inverter as it is

hot and you may get burnt.

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 install or operate if the inverter is damaged or has parts missing.

When carrying the inverter, do not hold it by the front cover or setting dial; it may

fall off or fail.

Do not stand or rest heavy objects on the inverter.

Check the inverter mounting orientation is correct.

Prevent other conductive bodies as screws and metal fragments or other

flammable substance as oil from entering the inverter.

As the inverter is a precision instrument, do not drop or subject it to impact.

Use the inverter under the following environmental conditions: This could cause

the inverter damage.

*Temperatures applicable for a short time, e.g. in transit.

Environment

Ambient

Temperature -10°C to +50°C (non-freezing)

Ambient humidity 90%RH maximum (non-condensing)

Storage

temperature -20°C to +65°C *

Atmosphere Indoors (free from corrosive gas, flammable gas, oil mist,

dust and dirt)

Altitude/

vibration Maximum 1000m above sea level for standard operation.

After that derate by 3% for every extra 500m up to 2500m

(91%). 5.9m/s2or less (conforming to JIS C 60068-2-6)

A-3

(2) Wiring

(3) Trial run

(4) Operation

CAUTION

Do not fit capacitive equipment such as power factor correction capacitor, radio

noise filter (option FR-BIF(-H)) or surge suppressor to the output of the inverter.

The connection orientation of the output cables U, V, W to the motor will affect the

direction of rotation of the motor.

CAUTION

Check all parameters, and ensure that the machine will not be damaged by a

sudden start-up.

When the load GD2is small (at the motor GD or smaller) for 400V from 1.5K to 3.7K, the

output current may vary when the output frequency is in the 20Hz to 30Hz range.

If this is a problem, set the Pr.72 "PWM frequency selection" to 6kHz or higher.

(When setting the PWM to a higher frequency, check for noise or leakage current

problem and take countermeasures against it.)

WARNING

When you have chosen the retry function, stay away from the equipment as it will

restart suddenly after an alarm stop.

The [STOP] key is valid only when the appropriate function setting has been made.

Prepare an emergency stop switch separately.

Make sure that the start signal is off before resetting the inverter alarm. A failure to

do so may restart the motor suddenly.

The load used should be a three-phase induction motor only. Connection of any

other electrical equipment to the inverter output may damage the equipment.

Do not modify the equipment.

Do not perform parts removal which is not instructed in this manual. Doing so may

lead to fault or damage of the inverter.

A-4

(5) Emergency stop

(6) Maintenance, inspection and parts replacement

(7) Disposing of the inverter

(8) General instructions

CAUTION

The electronic thermal relay function does not guarantee protection of the motor

from overheating.

Do not use a magnetic contactor on the inverter input for frequent starting/stopping

of the inverter.

Use a noise filter to reduce the effect of electromagnetic interference. Otherwise

nearby electronic equipment may be affected.

Take measures to suppress harmonics. Otherwise power supply harmonics from

the inverter may heat/damage the power capacitor and generator.

When a 400V class motor is inverter-driven, please use an insulation-enhanced

motor or measures taken to suppress surge voltages. Surge voltages attributable to

the wiring constants may occur at the motor terminals, deteriorating the insulation of

the motor.

When parameter clear or all clear is performed, reset the required parameters

before starting operations. Each parameter returns to the factory setting.

The inverter can be easily set for high-speed operation. Before changing its

setting, fully examine the performances of the motor and machine.

In addition to the inverter's holding function, install a holding device to ensure safety.

Before running an inverter which had been stored for a long period, always

perform inspection and test operation.

CAUTION

Provide a safety backup such as an emergency brake which will prevent the

machine and equipment from hazardous conditions if the inverter fails.

When the breaker on the inverter primary side trips, check for the wiring fault (short

circuit), damage to internal parts of the inverter, etc. Identify the cause of the trip,

then remove the cause and power on the breaker.

When any protective function is activated, take the appropriate corrective action,

then reset the inverter, and resume operation.

CAUTION

Do not carry out a megger (insulation resistance) test on the control circuit of the

inverter.

CAUTION

Treat as industrial waste.

Many of the diagrams and drawings in this instruction manual (detailed) show the inverter

without a cover, or partially open. Never operate the inverter in this manner. Always replace

the cover and follow this instruction manual (detailed) when operating the inverter.

CONTENTS

1. WIRING 1

1.1 Standard connection diagram and terminal specifications ..2

1.1.1 Standard connection diagram .......................................................................2

1.1.2 Explanation of main circuit terminals.............................................................3

1.2 Main circuit terminals ...............................................................6

1.2.1 Terminal block layout ....................................................................................6

1.2.2 Cables, wiring length, and crimping terminals...............................................7

1.2.3 Wiring instructions.........................................................................................8

1.2.4 Selection of peripheral devices .....................................................................9

1.2.5 Leakage current and installation of earth leakage circuit breaker...............10

1.2.6 Power-off and magnetic contactor (MC)......................................................14

1.2.7 Regarding the installation of the power factor improving reactor................15

1.2.8 Regarding noise and the installation of a noise filter...................................16

1.2.9 Earthing precautions ...................................................................................17

1.2.10 Power supply harmonics.............................................................................18

1.2.11 Inverter-driven 400V class motor ................................................................19

1.3 How to use the control circuit terminals...............................20

1.3.1 Terminal block layout ..................................................................................20

1.3.2 Wiring instructions.......................................................................................20

1.3.3 Changing the control logic...........................................................................21

1.4 Input terminals.........................................................................23

1.4.1 Run (start) and stop (STF, STR, STOP) .....................................................23

1.4.2 Connection of frequency setting potentiometer and

output frequency meter (10, 2, 5, 4, AU).....................................................26

1.4.3 External frequency selection (REX, RH, RM, RL).......................................27

1.4.4 Indicator connection and adjustment (AM)..................................................29

1.4.5 Control circuit common terminals (PC, 5, SE).............................................30

1.4.6 Signal inputs by contactless switches.........................................................30

1.5 How to use the input signals

(assigned terminals RL, RM, RH, STR)..................................31

1.5.1 Multi-speed setting (RL, RM, RH, REX signals):

Pr. 60 to Pr. 63 setting "0, 1, 2, 8"

Remote setting (RL, RM, RH signals):

Pr. 60 to Pr. 63 setting "0, 1, 2"...................................................................31

1.5.2 Second function selection (RT signal): Pr. 60 to Pr. 63 setting "3" .............31

1.5.3 Current input selection "AU signal": Pr. 60 to Pr. 63 setting "4"..................31

1.5.4 Start self-holding selection (STOP signal): Pr. 60 to Pr. 63 setting "5"....... 32

1.5.5 Output shut-off (MRS signal): Pr. 60 to Pr. 63 setting "6"........................... 32

1.5.6 External thermal relay input: Pr. 60 to Pr. 63 setting "7"............................. 33

1.5.7 Jog operation (JOG signal): Pr. 60 to Pr. 63 setting "9".............................. 33

1.5.8 Reset signal: Pr. 60 to Pr. 63 setting "10"................................................... 34

1.5.9 PID control valid terminal: Pr. 60 to Pr. 63 setting "14"............................... 35

1.5.10 PU operation/external operation switchover: Pr. 60 to Pr. 63 setting "16".. 35

1.6 Connection to the Stand-Alone Option.................................36

1.6.1 Connection of the brake unit (BU type)....................................................... 36

1.6.2 Connection of the high power factor converter (FR-HC)............................. 37

1.6.3 Connection of the power regeneration common converter (FR-CV)........... 38

1.7 Handling of the RS-485 connector ........................................39

1.7.1 Connection of the parameter unit (FR-PU04)............................................. 39

1.7.2 Wiring of RS-485 communication ............................................................... 40

1.8 Design information .................................................................43

2. FUNCTIONS 45

2.1 Function (Parameter) list........................................................46

2.2 List of parameters classified by purpose of use..................59

2.3 Explanation of functions (parameters) .................................61

2.3.1 Torque boost (Pr. 0 , Pr. 46 ) ...................................................................... 61

2.3.2 Maximum and minimum frequency (Pr. 1 , Pr. 2 ) ...................................... 62

2.3.3 Base frequency, base frequency voltage (Pr.3 , Pr.19 , Pr.47 ).................. 63

2.3.4 Multi-speed operation (Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 80 to Pr. 87)64

2.3.5 Acceleration/deceleration time (Pr. 7 , Pr. 8 , Pr. 20 , Pr. 44 , Pr. 45 ) ....... 65

2.3.6 Selection and protection of a motor (Pr. 9 , Pr. 71 , H7 )............................ 67

2.3.7 DC injection brake (Pr. 10 , Pr. 11 , Pr. 12 ) ............................................... 69

2.3.8 Starting frequency (Pr. 13 )......................................................................... 70

2.3.9 Load pattern selection (Pr. 14 )................................................................... 71

2.3.10 Jog operation (Pr.15 , Pr.16 )...................................................................... 72

2.3.11 RUN key rotation direction selection (Pr.17 ).............................................. 72

2.3.12 Stall prevention function and current limit function (Pr. 21 ) ....................... 73

2.3.13 Stall prevention (Pr. 22 , Pr. 23 , Pr. 28 ).................................................... 75

2.3.14 Acceleration/deceleration pattern (Pr. 29 ) ................................................. 77

2.3.15 Extended function display selection (Pr. 30 ).............................................. 78

2.3.16 Frequency jump (Pr. 31 to Pr. 36 )............................................................. 78

2.3.17 Speed display (Pr. 37 ) ............................................................................... 79

III

CONTENTS

2.3.18 Biases and gains of the frequency setting voltage (current)

(Pr. 38 , Pr. 39 , C2 to C7 ).........................................................................80

2.3.19 Start-time earth fault detection selection (Pr. 40 ).......................................84

2.4 Output terminal function parameters....................................84

2.4.1 Up-to-frequency (Pr. 41 ).............................................................................84

2.4.2 Output frequency detection (Pr. 42 , Pr. 43 )...............................................85

2.5 Current detection function parameters.................................86

2.5.1 Output current detection functions (Pr. 48 , Pr. 49 )....................................86

2.5.2 Zero current detection (Pr. 50 , Pr. 51 ).......................................................87

2.6 Display function parameters..................................................88

2.6.1 Monitor display (Pr. 52 , Pr. 54 )..................................................................88

2.6.2 Setting dial function selection (Pr. 53 )........................................................89

2.6.3 Monitoring reference (Pr. 55 , Pr. 56 ).........................................................90

2.7 Restart operation parameters ................................................90

2.7.1 Restart setting (Pr. 57 , Pr. 58 , H6 )...........................................................90

2.8 Additional function parameters .............................................93

2.8.1 Remote setting function selection (Pr. 59 ).................................................93

2.9 Terminal function selection parameters ...............................96

2.9.1 Input terminal function selection (Pr. 60 , Pr. 61 , Pr. 62 , Pr. 63 )..............96

2.9.2 Output terminal function selection (Pr. 64 , Pr. 65 ) ....................................98

2.10 Operation selection function parameters .............................99

2.10.1 Retry function (Pr. 66 , Pr. 67 , Pr. 68 , Pr. 69 ) ..........................................99

2.10.2 PWM carrier frequency and long wiring mode (Pr. 70 , Pr. 72 )................101

2.10.3 Voltage input selection (Pr. 73 )................................................................102

2.10.4 Input filter time constant (Pr. 74 )..............................................................103

2.10.5 Reset selection/PU stop selection (Pr. 75 )...............................................103

2.10.6 Cooling fan operation selection (Pr. 76 )...................................................105

2.10.7 Parameter write disable selection (Pr. 77 ) ...............................................106

2.10.8 Reverse rotation prevention selection (Pr. 78 ).........................................107

2.10.9 Operation mode selection (Pr. 79 ) ...........................................................107

2.10.10PID control (Pr. 88 to Pr. 94 )...................................................................111

2.11 Auxiliary parameters.............................................................118

2.11.1 Slip compensation (Pr. 95 , Pr. 96 , Pr. 97 )..............................................118

2.11.2 Automatic torque boost selection (Pr. 98 )................................................119

2.11.3 Motor primary resistance (Pr. 99 ).............................................................120

2.12 Maintenance parameters ......................................................120

2.12.1 Maintenance output function (H1, H2 )..................................................... 120

2.12.2 Current average value monitor signal (H3, H4, H5)................... 121

2.13 Calibration parameters.........................................................124

2.13.1 Meter (frequency meter) calibration (C1 )................................................. 124

2.14 Clear parameters...................................................................127

2.14.1 Parameter clear (CLr ) .............................................................................. 127

2.14.2 Alarm history clear (ECL )......................................................................... 127

2.15 Communication parameters.................................................128

2.15.1 Communication settings (n1 to n7 , n11 )................................................ 130

2.15.2 Operation and speed command source (n8 , n9 ) .................................... 145

2.15.3 Link startup mode selection (n10 )............................................................ 146

2.15.4 E2PROM write selection (n12 )................................................................. 148

2.16 Parameter unit (FR-PU04) setting........................................149

2.16.1 PU display language selection (n13 ) ....................................................... 149

2.16.2 PU buzzer control (n14 )........................................................................... 149

2.16.3 PU contrast adjustment (n15 ).................................................................. 150

2.16.4 PU main display screen data selection (n16 )........................................... 150

2.16.5 Disconnected PU detection/PU setting lock selection (n17 ).................... 151

3. PROTECTIVE FUNCTIONS 153

3.1 Errors (Alarms)......................................................................154

3.1.1 Error (alarm) definitions ............................................................................ 155

3.1.2 To know the operating status at the occurrence of alarm

(only when FR-PU04 is used)................................................................... 163

3.1.3 Correspondence between digital and actual characters........................... 163

3.1.4 Resetting the inverter................................................................................ 163

3.2 Troubleshooting....................................................................164

3.2.1 Motor remains stopped............................................................................. 164

3.2.2 Motor rotates in opposite direction............................................................ 165

3.2.3 Speed greatly differs from the setting....................................................... 165

3.2.4 Acceleration/deceleration is not smooth................................................... 165

3.2.5 Motor current is large................................................................................ 165

3.2.6 Speed does not increase.......................................................................... 165

3.2.7 Speed varies during operation.................................................................. 165

3.2.8 Operation mode is not changed properly.................................................. 166

3.2.9 Operation panel display is not operating................................................... 166

3.2.10 Parameter write cannot be performed ...................................................... 166

CONTENTS

3.2.11 Motor produces annoying sound...............................................................166

4. SPECIFICATIONS 167

4.1 Specification list....................................................................168

4.1.1 Ratings......................................................................................................168

4.1.2 Common specifications.............................................................................170

4.2 Outline drawings ...................................................................172

APPENDIX 175

APPENDIX 1 Parameter Instruction Code List .............................176

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