Mitsubishi Electric FR-S520E Series Bedienungsanleitung

TRANSISTORIZED INVERTER

FR-S500

INSTRUCTION MANUAL (Detailed)

FUNCTIONS

Chapter 2

HEAD OFFICE:TOKYO BLDG MARUNOUCHI TOKYO 100-8310

WIRING

Chapter 1

PROTECTIVE

FUNCTIONS

Chapter 3

SPECIFICATIONS

Chapter 4

FR-S500E

TRANSISTORIZED INVERTER INSTRUCTION MANUAL (Detailed)

SIMPLE INVERTER

FR-S520E-0.1K to 3.7K (-C)

FR-S540E-0.4K to 3.7K

FR-S520SE-0.1K to 1.5K

FR-S510WE-0.1K to 0.75K

IB(NA)-0600152E-C (0706) MEE Printed in Japan Specifications subject to change without notice.

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-0600151E] 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

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

may get an electric shock.

zDo 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.

zEven 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.

zBefore 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.

zThis inverter must be earthed (grounded). Earthing (grounding) must conform to

the requirements of national and local safety regulations and electrical codes.

(NEC section 250, IEC 536 class 1 and other applicable standards)

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

fully competent to do the work.

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

or be injured.

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

shock.

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

Otherwise, you may get an electric shock.

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

cooling fan while power is on.

zWhen 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

zInstall the inverter and brake resistor on an incombustible wall without holes, etc.

Installing the inverter and brake resistor directly on or near a combustible surface could

lead to a fire.

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

large current could cause a fire.

zWhen using a brake resistor, make up a sequence that will turn off power when an

alarm signal is output. Otherwise, the brake resistor may excessively overheat due

to damage of the brake transistor and such, causing a fire.

Do not connect the resistor directly to the DC terminals P and N. This could cause a fire.

CAUTION

zApply only the voltage specified in the instruction manual to each terminal to

prevent damage, etc.

zAlways connect to the correct terminal to prevent damage, etc.

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

zWhile 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

zWhen carrying products, use correct lifting gear to prevent injury.

zDo not stack the inverter boxes higher than the number recommended.

zEnsure that installation position and material can withstand the weight of the

inverter. Install according to the information in the instruction manual.

zDo not install or operate if the inverter is damaged or has parts missing.

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

fall off or fail.

zDo not stand or rest heavy objects on the inverter.

zCheck the inverter mounting orientation is correct.

zPrevent other conductive bodies as screws and metal fragments or other

flammable substance as oil from entering the inverter.

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

zUse 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)

(-10°C to +40°C for totally enclosed structure feature)

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 Max.1000m above sea level 5.9m/s2or less

A-3

(2) Wiring

(3) Trial run

(4) Operation

CAUTION

zDo not fit capacitive equipment such as power factor correction capacitor,

capacitor type filter (option FR-BIF(-H)) or surge suppressor to the output of the

inverter.

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

direction of rotation of the motor.

CAUTION

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

sudden start-up.

zWhen 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

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

restart suddenly after an alarm stop.

zSince the [STOP] key is valid only when functions are set (refer to page 115),

provide a circuit and switch separately to make an emergency stop (power off,

mechanical brake operation for emergency stop, etc).

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

do so may restart the motor suddenly.

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

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

zDo not modify the equipment.

zDo 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

zThe electronic thermal relay function does not guarantee protection of the motor

from overheating.

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

of the inverter.

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

nearby electronic equipment may be affected.

zTake measures to suppress harmonics. Otherwise power supply harmonics from

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

zWhen 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.

zWhen parameter clear or all clear is performed, reset the required parameters

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

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

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

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

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

perform inspection and test operation.

CAUTION

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

machine and equipment from hazardous conditions if the inverter fails.

zWhen 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.

zWhen any protective function is activated, take the appropriate corrective action,

then reset the inverter, and resume operation.

CAUTION

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

inverter.

CAUTION

zTreat 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............................................... 8

1.2.3 Wiring instructions ......................................................................................... 9

1.2.4 Selection of peripheral devices ................................................................... 10

1.2.5 Leakage current and installation of earth (ground) leakage circuit breaker 12

1.2.6 Power-off and magnetic contactor (MC)...................................................... 16

1.2.7 Regarding the installation of the reactor...................................................... 17

1.2.8 Regarding noise and the installation of a noise filter................................... 18

1.2.9 Earthing (Grounding) precautions ............................................................... 19

1.2.10 Power supply harmonics ............................................................................. 20

1.2.11 Harmonic suppression guideline ................................................................. 21

1.2.12 Inverter-driven 400V class motor ................................................................ 25

1.3 How to use the control circuit terminals ...............................26

1.3.1 Terminal block layout .................................................................................. 26

1.3.2 Wiring instructions ....................................................................................... 26

1.3.3 Changing the control logic........................................................................... 27

1.4 Input terminals.........................................................................29

1.4.1 Run (start) and stop (STF, STR, STOP) ..................................................... 29

1.4.2 Connection of frequency setting potentiometer and

output frequency meter (10, 2, 5, 4, AU)..................................................... 32

1.4.3 External frequency selection (REX, RH, RM, RL) ....................................... 33

1.4.4 Indicator connection and adjustment (FM) .................................................. 35

1.4.5 Control circuit common terminals (SD, 5, SE)............................................. 37

1.4.6 Signal inputs by contactless switches ......................................................... 37

1.5 How to use the input signals

(assigned terminals RL, RM, RH, STR)..................................38

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" ................................................................... 38

1.5.2 Second function selection (RT signal): Pr. 60 to Pr. 63 setting "3" ............. 38

1.5.3 Current input selection "AU signal": Pr. 60 to Pr. 63 setting "4".................. 38

1.5.4 Start self-holding selection (STOP signal): Pr. 60 to Pr. 63 setting "5"....... 39

1.5.5 Output shut-off (MRS signal): Pr. 60 to Pr. 63 setting "6" ........................... 39

1.5.6 External thermal relay input: Pr. 60 to Pr. 63 setting "7"............................. 40

1.5.7 Jog operation (JOG signal): Pr. 60 to Pr. 63 setting "9".............................. 40

1.5.8 Reset signal: Pr. 60 to Pr. 63 setting "10"................................................... 41

1.5.9 PID control valid terminal: Pr. 60 to Pr. 63 setting "14"............................... 42

1.5.10 PU operation/external operation switchover: Pr. 60 to Pr. 63 setting "16".. 42

1.6 Connection to the stand-alone option .................................. 43

1.6.1 Connection of the dedicated external brake resistor (option) (FR-S520E-0.4K

to 3.7K only)................................................................................................ 43

1.6.2 Connection of the brake unit (BU type)....................................................... 44

1.6.3 Connection of the high power factor converter (FR-HC)............................. 45

1.6.4 Connection of the power regeneration common converter (FR-CV)........... 46

1.7 Handling of the RS-485 connector ........................................47

1.7.1 Connection of the parameter unit (FR-PU04) ............................................. 47

1.7.2 Wiring of RS-485 communication ............................................................... 48

1.8 Design information ................................................................. 51

1.9 Failsafe of the system which uses the inverter....................52

2. FUNCTIONS 55

2.1 Function (Parameter) list........................................................56

2.2 List of parameters classified by purpose of use..................69

2.3 Explanation of functions (parameters) ................................. 71

2.3.1 Torque boost (Pr. 0 , Pr. 46 ) ...................................................................... 71

2.3.2 Maximum and minimum frequency (Pr. 1 , Pr. 2 ) ...................................... 72

2.3.3 Base frequency, base frequency voltage (Pr.3 , Pr.19 , Pr.47 ).................. 73

2.3.4 Multi-speed operation (Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 80 to Pr. 87)75

2.3.5 Acceleration/deceleration time (Pr. 7 , Pr. 8 , Pr. 20 , Pr. 44 , Pr. 45 ) ....... 76

2.3.6 Selection and protection of a motor (Pr. 9 , Pr. 71 , H7 )............................ 78

2.3.7 DC injection brake (Pr. 10 , Pr. 11 , Pr. 12 ) ............................................... 80

2.3.8 Starting frequency (Pr. 13 )......................................................................... 81

2.3.9 Load pattern selection (Pr. 14 )................................................................... 82

2.3.10 Jog operation (Pr.15 , Pr.16 )...................................................................... 83

2.3.11 RUN key rotation direction selection (Pr.17 ).............................................. 83

2.3.12 Stall prevention function and current limit function (Pr. 21 ) ....................... 84

2.3.13 Stall prevention (Pr. 22 , Pr. 23 , Pr. 28 ) .................................................... 86

III

CONTENTS

2.3.14 Acceleration/deceleration pattern (Pr. 29 ).................................................. 88

2.3.15 Extended function display selection (Pr. 30 ) .............................................. 89

2.3.16 Frequency jump (Pr. 31 to Pr. 36 )............................................................. 89

2.3.17 Speed display (Pr. 37 )................................................................................ 90

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

(Pr. 38 , Pr. 39 , C2 to C7 )......................................................................... 91

2.3.19 Start-time earth (ground) fault detection selection (Pr. 40 ) ........................ 95

2.4 Output terminal function ........................................................95

2.4.1 Up-to-frequency sensitivity (Pr. 41 )............................................................ 95

2.4.2 Output frequency detection (Pr. 42 , Pr. 43 )............................................... 96

2.5 Current detection function .....................................................97

2.5.1 Output current detection functions (Pr. 48 , Pr. 49 ).................................... 97

2.5.2 Zero current detection (Pr. 50 , Pr. 51 )....................................................... 98

2.6 Display function ......................................................................99

2.6.1 Monitor display (Pr. 52 , Pr. 54 ).................................................................. 99

2.6.2 Setting dial function selection (Pr. 53 )...................................................... 100

2.6.3 Monitoring reference (Pr. 55 , Pr. 56 )....................................................... 101

2.7 Restart operation function ...................................................101

2.7.1 Restart setting (Pr. 57 , Pr. 58 , H6 ) ......................................................... 101

2.8 Additional function................................................................104

2.8.1 Remote setting function selection (Pr. 59 ) ............................................... 104

2.9 Terminal function selection..................................................108

2.9.1 Input terminal function selection (Pr. 60 , Pr. 61 , Pr. 62 , Pr. 63 ) ............ 108

2.9.2 Output terminal function selection (Pr. 64 , Pr. 65 ) .................................. 110

2.10 Operation selection function................................................111

2.10.1 Retry function (Pr. 66 , Pr. 67 , Pr. 68 , Pr. 69 ) ........................................ 111

2.10.2 PWM carrier frequency and long wiring mode (Pr. 70 , Pr. 72 )................ 113

2.10.3 Voltage input selection (Pr. 73 ) ................................................................ 114

2.10.4 Input filter time constant (Pr. 74 ) .............................................................. 115

2.10.5 Reset selection/PU stop selection (Pr. 75 )............................................... 115

2.10.6 Cooling fan operation selection (Pr. 76 ) ................................................... 117

2.10.7 Parameter write disable selection (Pr. 77 ) ............................................... 118

2.10.8 Reverse rotation prevention selection (Pr. 78 )......................................... 119

2.10.9 Operation mode selection (Pr. 79 ) ........................................................... 119

2.10.10PID control (Pr. 88 to Pr. 94 )................................................................... 123

2.11 Auxiliary function ..................................................................131

2.11.1 Slip compensation (Pr. 95 , Pr. 96 , Pr. 97 ).............................................. 131

2.11.2 Automatic torque boost selection (Pr. 98 )................................................ 132

2.11.3 Motor primary resistance (Pr. 99 ) ............................................................ 133

2.12 Maintenance function ........................................................... 133

2.12.1 Maintenance output function (H1, H2 ) ..................................................... 133

2.12.2 Current average value monitor signal (H3, H4, H5)................... 134

2.13 Brake parameters (FR-S520E-0.4K to 3.7K only) ............... 137

2.13.1 Regenerative braking operation (b1 , b2 ) ................................................ 137

2.14 Calibration parameters ......................................................... 138

2.14.1 Meter (frequency meter) calibration (C1 )................................................. 138

2.15 Clear parameters................................................................... 141

2.15.1 Parameter clear (CLr ) .............................................................................. 141

2.15.2 Alarm history clear (ECL )......................................................................... 141

2.16 Communication parameters................................................. 142

2.16.1 Communication settings (n1 to n7 , n11 ) ................................................ 144

2.16.2 Operation and speed command source (n8 , n9 ) .................................... 160

2.16.3 Link startup mode selection (n10 )............................................................ 161

2.16.4 EEPROM write selection (n12 ) ................................................................ 163

2.17 Parameter unit (FR-PU04) setting........................................ 164

2.17.1 PU display language selection (n13 ) ....................................................... 164

2.17.2 PU buzzer control (n14 ) ........................................................................... 164

2.17.3 PU contrast adjustment (n15 ) .................................................................. 165

2.17.4 PU main display screen data selection (n16 )........................................... 165

2.17.5 Disconnected PU detection/PU setting lock selection (n17 ) .................... 166

3. PROTECTIVE FUNCTIONS 169

3.1 Errors (Alarms)...................................................................... 170

3.1.1 Error (alarm) definitions ............................................................................ 171

3.1.2 To know the operating status at the occurrence of alarm

(only when FR-PU04 is used) ................................................................... 179

3.1.3 Correspondence between digital and actual characters ........................... 179

3.1.4 Resetting the inverter................................................................................ 179

3.1.5 Checking of the alarm history ................................................................... 180

3.2 Troubleshooting.................................................................... 181

3.2.1 Motor remains stopped ............................................................................. 181

3.2.2 Motor rotates in opposite direction............................................................ 182

3.2.3 Speed greatly differs from the setting ....................................................... 182

CONTENTS

3.2.4 Acceleration/deceleration is not smooth.................................................... 182

3.2.5 Motor current is large ................................................................................ 182

3.2.6 Speed does not increase........................................................................... 182

3.2.7 Speed varies during operation .................................................................. 182

3.2.8 Operation mode is not changed properly .................................................. 183

3.2.9 Operation panel display is not operating................................................... 183

3.2.10 Parameter write cannot be performed....................................................... 183

3.2.11 Motor produces annoying sound ............................................................... 183

3.3 Precautions for maintenance and inspection.....................184

3.3.1 Precautions for maintenance and inspection ............................................ 184

3.3.2 Inspection item .......................................................................................... 184

3.3.3 Periodic inspection .................................................................................... 184

3.3.4 Insulation resistance test using megger .................................................... 185

3.3.5 Pressure test ............................................................................................. 185

3.3.6 Daily and periodic inspection..................................................................... 186

3.3.7 Checking the inverter and converter module............................................. 188

3.3.8 Replacement of parts ................................................................................ 189

3.3.9 Measurement of main circuit voltages, currents and powers .................... 192

4. SPECIFICATIONS 195

4.1 Specification list....................................................................196

4.1.1 Ratings ...................................................................................................... 196

4.1.2 Common specifications ............................................................................. 200

4.2 Outline dimension drawings ................................................202

APPENDIX 205

APPENDIX 1 Parameter instruction code list ...............................206

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