Mitsubishi Electronics 520 540 User Manual
TRANSISTORIZED INVERTER
FR-F500J
INSTRUCTION MANUAL (Detailed)
AIR-CONDITIONING INVERTER
FR-F520J-0.4K to 15K (F)
FR-F540J-0.4K to 15K (F)
WIRING
FUNCTIONS
PROTECTIVE
FUNCTIONS
SPECIFICATIONS
Chapter 1
Chapter 2
Chapter 3
Chapter 4
Thank you for choosing this Mitsubishi Transistorized inverter.
This instruction manual (detailed) provides instructions for advanced use of the FR-
F500J series inverters.
Incorrect handling might cause an unexpected fault. Before using the inverter, always
read this instruction manual and the instruction manual (basic) [IB-0600129E]
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".
WARNING
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.
CAUTION
1. Electric Shock Prevention
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 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.
You may get 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.
A-1
2. Fire Prevention
CAUTION
zInstall the inverter (filter pack) on an incombustible wall without holes, etc.
Mounting it to or near combustible material can cause a fire.
zIf the inverter has become faulty, switch off the inverter power. A continuous flow of
large current could cause a fire.
z
Do not connect the resistor directly to the DC terminals P and N. This coule cause a fire.
3. Injury Prevention
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 (filter
pack) or break register 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
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 (filter pack) 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 (filter pack).
zAs the inverter (filter pack) 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 (filter pack) damage.
Surrounding Air
Temperature
Ambient
humidity
Storage
temperature
Atmosphere
Environment
Altitude/
vibration
*1 Temperatures applicable for a short time, e.g. in transit.
*2 When using with the filter pack installed on the rear panel of the FR-F520J-15K or
FR-F540J-15K, do not install this combination on moving objects or places that
have vibrations exceeding 1.96m/s
-10°C to +50°C (non-freezing)
90%RH maximum (non-condensing)
-20°C to +65°C *1
Indoors (free from corrosive gas, flammable gas, oil mist,
dust and dirt)
Max.1000m above sea level 5.9m/s
2
.
2
or less *2
A-2
(2) Wiring
CAUTION
zDo 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.
zThe 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
zCheck all parameters, and ensure that the machine will not be damaged by a
sudden start-up.
zWhen the load GD
output current may vary when the output frequency is in the 20Hz to 30Hz range.
If this is a problem, set the Pr.72 "PWM frequency selection" to 6kHz or higher.
(When setting the PWM to a higher frequency, check for noise or leakage current
problem and take countermeasures against it.)
(4) Operation
2
is small (at the motor GD or smaller) for 400V from 1.5K to 3.7K, the
WARNING
zWhen you have chosen the retry function, stay away from the equipment as it will
restart suddenly after an alarm stop.
zSince the key is valid only when functions are set (refer to page 116),
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.
STOP
RESET
A-3
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.
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.
(5) Emergency stop
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 of the inner 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.
(6) Maintenance, inspection and parts replacement
CAUTION
zDo not carry out a megger (insulation resistance) test on the control circuit of the
inverter.
(7) Disposing of the inverter
CAUTION
zTreat 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 run the inverter in this status. Always replace the cover and
follow this instruction manual when operating the inverter.
A-4
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.................................................................... 7
1.2.1 Terminal block layout ...................................................................................... 7
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 .. 11
1.2.6 Power-off and magnetic contactor (MC)........................................................ 15
1.2.7 Regarding the installation of the reactor........................................................ 16
1.2.8 Regarding noise (EMI) and the installation of a noise filter ........................... 17
1.2.9 Earthing (Grounding) precautions ................................................................. 18
1.2.10 Power supply harmonics............................................................................... 19
1.2.11 Harmonic suppression guideline ................................................................... 20
1.2.12 Inverter-driven 400V class motor .................................................................. 24
1.3 How to use the control circuit terminals ...................................... 25
1.3.1 Terminal block layout .................................................................................... 25
1.3.2 Wiring instructions ......................................................................................... 25
1.3.3 Changing the control logic............................................................................. 26
1.4 Input terminals............................................................................ 28
1.4.1 Run (start) and stop (STF, STR, STOP) ....................................................... 28
1.4.2 Connection of frequency setting potentiometer and
output frequency meter (10, 2, 5, 4, AU) ....................................................... 31
1.4.3 External frequency selection (REX, RH, RM, RL)......................................... 32
1.4.4 Indicator connection and adjustment (FM).................................................... 34
1.4.5 Control circuit common terminals (SD, 5, SE)............................................... 36
1.4.6 Signal inputs by contactless switches ........................................................... 36
1.5 How to use the input signals
(assigned terminals AU, RM, RH, STR) ..................................... 37
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" ..................................................................... 37
1.5.2 Second function selection (RT signal): Pr. 60 to Pr. 63 setting "3" ............... 37
1.5.3 Current input selection "AU signal": Pr. 60 to Pr. 63 setting "4" .................... 37
1.5.4 Start self-holding selection (STOP signal): Pr. 60 to Pr. 63 setting "5" ......... 38
1.5.5 Output shut-off (MRS signal): Pr. 60 to Pr. 63 setting "6" ............................. 38
CONTENTS
I
1.5.6 External thermal relay input: Pr. 60 to Pr. 63 setting "7"................................39
1.5.7 Jog operation (JOG signal): Pr. 60 to Pr. 63 setting "9".................................39
1.5.8 Reset signal: Pr. 60 to Pr. 63 setting "10"......................................................40
1.5.9 PID control valid terminal: Pr. 60 to Pr. 63 setting "14"..................................41
1.5.10 PU operation/external operation switchover: Pr. 60 to Pr. 63 setting "16".....41
1.6 Connection to the stand-alone option .........................................42
1.6.1 Connection of the brake unit (FR-BU2)..........................................................42
1.6.2 Connection of the brake unit (FR-BU)............................................................44
1.6.3 Connection of the brake unit (BU type)..........................................................45
1.6.4 Connection of the high power factor converter (FR-HC)................................46
1.6.5 Connection of the power regeneration common converter (FR-CV)..............47
1.7 Handling of the RS-485 connector..............................................48
1.7.1 Connection of the parameter unit (FR-PU04) ................................................48
1.7.2 Wiring of RS-485 communication ..................................................................48
1.8 Design information ...................................................................... 52
1.9 Failsafe of the system which uses the inverter ...........................53
2. FUNCTIONS 57
2.1 Function (Parameter) list.............................................................58
2.2 List of parameters classified by purpose of use..........................71
2.3 Explanation of functions (parameters) ........................................73
2.3.1 Torque boost (Pr. 0 , Pr. 46 ) .........................................................................73
2.3.2 Maximum and minimum frequency (Pr. 1 , Pr. 2 ) .........................................74
2.3.3 Base frequency, base frequency voltage (Pr.3 , Pr.19 , Pr.47 ).....................75
2.3.4 Multi-speed operation (Pr. 4, Pr. 5, Pr. 6, Pr. 24 to Pr. 27, Pr. 80 to Pr. 87)..77
2.3.5 Acceleration/deceleration time (Pr. 7 , Pr. 8 , Pr. 20 , Pr. 44 , Pr. 45 ) ..........78
2.3.6 Selection and protection of a motor (Pr. 9 , Pr. 71 ).......................................80
2.3.7 DC injection brake (Pr. 10 , Pr. 11 , Pr. 12 ) ..................................................81
2.3.8 Starting frequency (Pr. 13 )............................................................................82
2.3.9 Load pattern selection (Pr. 14 )......................................................................83
2.3.10 Jog operation (Pr.15 , Pr.16 ).........................................................................84
2.3.11 RUN key rotation direction selection (Pr.17 ).................................................84
2.3.12 Stall prevention function and current limit function (Pr. 21 ) ..........................85
2.3.13 Stall prevention (Pr. 22 , Pr. 23 , Pr. 28 ) .......................................................87
2.3.14 Acceleration/deceleration pattern (Pr. 29 ) ....................................................89
2.3.15 Extended function display selection (Pr. 30 ).................................................90
2.3.16 Frequency jump (Pr. 31 to Pr. 36 )................................................................90
2.3.17 Speed display (Pr. 37 ) ..................................................................................91
2.3.18 Biases and gains of the frequency setting voltage (current)
(Pr. 38 , Pr. 39 , C2 to C7 ) ...........................................................................92
II
2.3.19 Start-time earth (ground) fault detection selection (Pr. 40 ) .......................... 96
2.4 Output terminal function ............................................................. 96
2.4.1 Up-to-frequency sensitivity (Pr. 41 ) .............................................................. 96
2.4.2 Output frequency detection (Pr. 42 , Pr. 43 )................................................. 97
2.5 Current detection function .......................................................... 98
2.5.1 Output current detection functions (Pr. 48 , Pr. 49 )...................................... 98
2.5.2 Zero current detection (Pr. 50 , Pr. 51 )......................................................... 99
2.6 Display function ........................................................................ 100
2.6.1 Monitor display (Pr. 52 , Pr. 54 ).................................................................. 100
2.6.2 Setting dial function selection (Pr. 53 )........................................................ 101
2.6.3 Monitoring reference (Pr. 55 , Pr. 56 )......................................................... 102
2.7 Restart operation...................................................................... 102
2.7.1 Restart setting (Pr. 57 , Pr. 58 )................................................................... 102
2.8 Additional function .................................................................... 105
2.8.1 Remote setting function selection (Pr. 59 ) ................................................. 105
2.9 Terminal function selection....................................................... 109
2.9.1 Input terminal function selection (Pr. 60 , Pr. 61 , Pr. 62 , Pr. 63 ) .............. 109
2.9.2 Output terminal function selection (Pr. 64 , Pr. 65 ) .................................... 111
2.10 Operation selection function ..................................................... 112
2.10.1 Retry function (Pr. 66 , Pr. 67 , Pr. 68 , Pr. 69 ) .......................................... 112
2.10.2 PWM carrier frequency (Pr. 70 , Pr. 72 ) ..................................................... 114
2.10.3 Voltage input selection (Pr. 73 ) .................................................................. 115
2.10.4 Input filter time constant (Pr. 74 ) ................................................................ 116
2.10.5 Reset selection/PU stop selection (Pr. 75 )................................................. 116
2.10.6 Cooling fan operation selection (Pr. 76 )..................................................... 118
2.10.7 Parameter write disable selection (Pr. 77 ) ................................................. 119
2.10.8 Reverse rotation prevention selection (Pr. 78 )........................................... 120
2.10.9 Operation mode selection (Pr. 79 ) ............................................................. 120
2.10.10PID control (Pr. 88 to Pr. 94 )..................................................................... 124
2.11 Auxiliary function ...................................................................... 132
2.11.1 Slip compensation (Pr. 95 , Pr. 96 , Pr. 97 )................................................ 132
2.11.2 Automatic torque boost selection (Pr. 98 ) .................................................. 133
2.11.3 Motor primary resistance (Pr. 99 )............................................................... 134
2.12 Maintenance function ............................................................... 134
2.12.1 Maintenance output function (H1, H2 )........................................................ 134
2.12.2 Output phase failure protection selection (H8 )........................................... 135
2.13 Calibration parameters ............................................................. 137
2.13.1 Meter (frequency meter) calibration (C1 ) ................................................... 137
2.14 Clear parameters...................................................................... 140
2.14.1 Parameter clear (CLr )................................................................................. 140
III
CONTENTS
2.14.2 Alarm history clear (ECL ) ............................................................................140
2.15 Communication parameters ...................................................... 141
2.15.1 Communication settings (n1 to n7 , n11 ) ...................................................143
2.15.2 Operation and speed command source (n8 , n9 ) .......................................158
2.15.3 Link startup mode selection (n10 )...............................................................159
2.15.4 EEPROM write selection (n12 ) ...................................................................161
2.16 Parameter unit (FR-PU04) setting.............................................162
2.16.1 PU display language selection (n13 ) ..........................................................162
2.16.2 PU buzzer control (n14 )..............................................................................162
2.16.3 PU contrast adjustment (n15 ) .....................................................................163
2.16.4 PU main display screen data selection (n16 )..............................................163
2.16.5 Disconnected PU detection/PU setting lock selection (n17 ) .......................164
3. PROTECTIVE FUNCTIONS 167
3.1 Errors (Alarms)..........................................................................168
3.1.1 Error (alarm) definitions ...............................................................................169
3.1.2 To know the operating status at the occurrence of alarm
(only when FR-PU04 is used)......................................................................177
3.1.3 Correspondence between digital and actual characters..............................177
3.1.4 Resetting the inverter ...................................................................................177
3.2 Troubleshooting ........................................................................178
3.2.1 Motor remains stopped ................................................................................178
3.2.2 Motor rotates in opposite direction...............................................................179
3.2.3 Speed greatly differs from the setting ..........................................................179
3.2.4 Acceleration/deceleration is not smooth ......................................................179
3.2.5 Motor current is large...................................................................................179
3.2.6 Speed does not increase .............................................................................179
3.2.7 Speed varies during operation .....................................................................179
3.2.8 Operation mode is not changed properly.....................................................180
3.2.9 Operation panel display is not operating......................................................180
3.2.10 Parameter write cannot be performed .........................................................180
3.2.11 Motor produces annoying sound..................................................................180
3.3 Precautions for maintenance and inspection ............................181
3.3.1 Precautions for maintenance and inspection...............................................181
3.3.2 Inspection item.............................................................................................181
3.3.3 Periodic inspection.......................................................................................181
3.3.4 Insulation resistance test using megger.......................................................182
3.3.5 Pressure test................................................................................................182
3.3.6 Daily and periodic inspection .......................................................................183
3.3.7 Replacement of parts...................................................................................186
3.3.8 Measurement of main circuit voltages, currents and powers .......................191
IV
4. SPECIFICATIONS 195
4.1 Specification list........................................................................ 196
4.1.1 Ratings ........................................................................................................ 196
4.1.2 Common specifications............................................................................... 198
4.2 Outline dimension drawings ..................................................... 200
APPENDIX 205
APPENDIX 1 Parameter instruction code list..................................... 206
APPENDIX 2 SERIAL number check................................................. 211
CONTENTS
V
1. WIRING
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 Standard connection diagram and terminal
specifications .....................................................
1.2 Main circuit terminals ........................................ 7
1.3 How to use the control circuit terminals.......... 25
1.4 Input terminals.................................................... 28
1.5 How to use the input signals (assigned
terminals AU, RM, RH, STR) ..............................
1.6 Connection to the stand-alone option.............. 36
1.7 Handling of the RS-485 connector.................... 48
1.8 Design information............................................. 52
1.9 Failsafe of the system which uses the inverter 53
<Abbreviations>
•PU
Operation panel and parameter unit (FR-PU04)
•Inverter
Mitsubishi transistorized inverter FR-F500J series
•FR-F500J
Mitsubishi transistorized inverter FR-F500J series
•Pr.
Parameter number
•Filter pack
FR-BFP
2
37
Chapter 1
Chapter 2
Chapter 3
Chapter 4
1
Standard connection diagram and terminal specifications
1.1 Standard connection diagram and terminal specifications
1.1.1 Standard connection diagram
zWith filter pack
*4
*4
*4
*4
Selected
SINK
*2
SOURCE
RS-485
connector
Inverter
*5
RUN
U
V
W
External transistor common
24VDC power supply
PC
Contact input common (source)
Take care not to short
terminals PC-SD.
*5
A
B
*5
*5
C
SE
Alarm output
Running
Open
collector
output
common
FM
Calibration
resistor
SD
Motor
IM
Earth (Ground)
Operation status
output
Open
collector
outputs
Indicator
1mA full-scale
Analog meter
(Digital indicator)
1mA
(+)
*1
3-phase AC
power supply
POINT
MCCB MC
Earth
*6
(Ground)
Jumper: Remove this
jumper to connect
the filter pack.
Control input
signals
(No voltage
input allowed)
Frequency setting signals (Analog)
Frequency setting
potentiometer
1/2W1kΩ
When using current input as the
frequency setting signal, turn the
AU signal on.
Forward rotation start
Reverse rotation start
Multi-speed
selection
Current input selection
Contact input common
*3
Current input(-)
4 to 20mADC(+)
Filter pack
R0
S0
T0
P1
GND
High speed
Middle speed
3
2
1
R
R/L1
S/L2
S
T/L3
T
P/+
P
P1
N/-
STF
STR
RH
RM
AU
SD
10
(+5V)
0 to 5VDC
2
0 to 10VDC
5
(Common)
4
(4 to 20mADC)
(-)
Control circuit terminalMain circuit terminal
REMARKS
*1. Not needed when the setting dial is used for calibration.
Used when calibration must be made near the frequency meter for such a reason as a remote frequency meter.
However, the frequency meter needle may not deflect to full-scale if the calibration resistor is connected.
In this case, use this resistor and setting dial together.
*2. You can switch the position of sink and source logic. Refer to page 26.
*3. When the setting potentiometer is used frequently, use a 2W1kΩ potentiometer.
*4. The terminal functions change with input terminal function selection (Pr. 60 to Pr. 63). (Refer to page 109.)
(RES, RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, X14, X16, (STR) signal selection)
*5. The terminal function changes with the setting of output terminal function selection (Pr. 64, Pr. 65). (Refer to
page 111.) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y95, LF, ABC signal selection)
*6. Connect the GND cable of the filter pack to the earth (ground) terminal of the inverter. Use the earth (ground)
terminal of the filter pack to earth (ground). For inverter earthing (grounding), earth (ground) the inverter
through the filter pack.
CAUTION
To prevent a malfunction due to noise, keep the signal cables more than 10cm away
from the power cables.
2
Standard connection diagram and terminal specifications
Without filter pack
MCCB
Earth (Ground)
MC
R/L1
S/L2
T/L3
U
V
W
P1
DC reactor
(FR-HEL/BEL: option)
P/+
N/-
1.1.2 Explanation of main circuit terminals
(1) Main circuit
zInverter
Motor
IM
Earth
(Ground)
Jumper: Remove
this jumper when
DC reactor is connected.
Termina l
Symbol
Terminal Name Description
R/L1, S/L2, T/L3 AC power input
U, V, W Inverter output
N/-
P/+, P1
DC voltage
common
Filter pack
connection
Earth (Ground)
Connect the R, S, T cables of the filter pack to these
terminals.
REMARKS
For the inverter without filter pack, connect these to the
commercial power supply.
Connect to a three-phase squirrel-cage motor.
DC voltage common terminal. This is not insulated from
the power and inverter output.
Remove the jumper across terminals P-P1 and connect
the P and P1 cables of the filter pack.
REMARKS
For the inverter without filter pack, remove the jumper
across terminals P-P1 and connect the optional DC
reactor (FR-HEL/BEL).
For earthing (grounding) the inverter chassis.
Connect the GND cable of the filter pack.
REMARKS
Earth (Ground) the inverter without filter pack.
1
WIRING
3
Standard connection diagram and terminal specifications
zFilter pack
Termin al
Symbol
R0, S0, T0
Terminal Name Description
Commercial power
supply input
Earth (Ground)
Crimping
Termin al
Terminal Name
Symbol
R, S, T
Inverter power
supply
P, P1 DC reactor terminal
Inverter earth
GND
(ground)
connection
Connect to the commercial power supply.
For earthing (grounding) the filter pack. Must be earthed
(grounded).
Cable
Color
Black Connect to the R, S, T of the inverter.
Red
Green and
yellow
stripes
Remove the jumper across terminals PP1 and connect to the P and P1 terminals
of the inverter.
Connect to the earth (ground) terminal of
the inverter. (Refer to page 2.)
Description
4
Standard connection diagram and terminal specifications
(2) Control circuit
Symbol Terminal Name Definition
Turn on the STF signal to
start forward rotation and
turn it off to stop.
Turn on the STR signal to
start reverse rotation and
turn it off to stop.
Turn on the RH, RM signals in
appropriate combinations to select
multiple speeds.
The priorities of the speed commands
are in order of jog, multi-speed setting
(RH, RM, RL, REX) and AU.
Only when the AU signal is turned on,
the inverter can be operated with the 4
to 20mADC frequency setting signal.
Turning the AU signal on makes voltage
input (across terminals 2-5) invalid.
Common terminal for contact input terminal (sink logic) and
terminal FM.
When connecting the transistor output (open collector
output), such as a programmable controller, when source
logic is selected, connect the external power supply
common for transistor output to this terminal to prevent a
malfunction caused by undesirable currents.
Common output terminal for 24VDC 0.1A power supply (PC
terminal).
Isolated from terminals 5 and SE.
When connecting the transistor output (open collector
output), such as a programmable controller, when sink logic
is selected, connect the external power supply common for
transistor output to this terminal to prevent a malfunction
caused by undesirable currents.
Common terminal for contact input terminal (source logic).
Can be used as 24VDC 0.1A power supply.
5VDC, Permissible load current 10mA.
STF
STR
RHRMMulti-speed
Contact input
AU
SD
(*1, *6)
Input signals
PC
(*1)
10
Forward rotation
start
Reverse rotation
start
selection
Current input
selection
Contact input
common (sink)
(initial setting)
External
transistor
common (source)
24VDC power
supply common
External
transistor
common (sink)
(initial setting)
Contact input
common (source)
24VDC power
supply
Frequency setting
power supply
When the STF and STR
signals are turned on
simultaneously, the stop
command is given.
The terminal
functions change
with input terminal
function selection
(Pr. 60 to Pr.63).
(*3)
1
WIRING
5
Standard connection diagram and terminal specifications
Symbol Terminal Name Definition
Inputting 0 to 5VDC (or 0 to 10V) provides the maximum output
Frequency setting
2
(voltage signal)
Frequency setting
4
(current signal)
Input signals
Frequency setting
Frequency setting
5
input common
A
BCAlarm output
Inverter
RUN
running
Open collector
Open collector
SE
common
Output signals
FM For meter
Indicator
frequency at 5V (10V) and makes input and output proportional.
Switch between 5V and 10V using Pr. 73 "0-5V, 0-10V selection".
Input resistance 10kΩ. Maximum permissible input voltage 20V
Input 4 to 20mADC. It is factory set at 0Hz for 4mA and at
60Hz for 20mA.
Maximum permissible input current 30mA. Input resistance
approximately 250Ω.
Turn ON signal AU for current input.
Turning the AU signal on makes voltage input invalid. Use any of
Pr. 60 to Pr. 63 (input terminal function selection) to set the AU
signal.
Frequency setting signal (terminal 2, 4) common terminal.
Do not earth (ground).
1 changeover contact output indicates
that the inverter protective function has
activated and the output stopped.
230VAC 0.3A, 30VDC 0.3A. Alarm:
discontinuity across B-C (continuity
across A-C), Normal: continuity across
B-C (discontinuity across A-C).(*5)
Switched low when the inverter output
frequency is equal to or higher than the
starting frequency (factory set to 0.5Hz
variable). Switched high during stop or
DC injection brake operation. (*2)
Permissible load 24VDC 0.1A (a
voltage drop is 3.4V maximum when
the signal is on)
Common terminal for inverter running terminal RUN.
The output signal across terminals FM-SD is factory set to about
1mA at 60Hz and is proportional to the corresponding output
frequency. Since output voltage is pulse waveform, a digital
meter can be connected.
Frequency permissible load current 1mA
Pulse specification 1440 pulses/s at 60Hz
The function of the
terminals changes
according to the
output terminal
function selection
(Pr. 64, Pr.65).
(*4)
(*6)
Using the parameter unit connection cable (FR-CB201 to
——
RS-485
connector
205), the parameter unit (FR-PU04) can be connected.
Communication operation can be performed using RS-485.
For details of RS-485 communication, refer to page 48.
Communication
*1. Do not connect terminals SD and PC each other or to the earth (ground).
For sink logic (factory setting), terminal SD acts as the common terminal of contact input.
For source logic, terminal PC acts as the common terminal of contact input. (Refer to
page 26 for switching method.)
*2. Low indicates that the open collector output transistor is on (conducts). High indicates
that the transistor is off (does not conduct).
*3. RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, RES, X14, X16, (STR) signal
selection (Refer to page 109.)
*4. RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, Y95, LF, ABC signal selection (Refer to
page 111.)
*5. To be compliant with the European Directive (Low Voltage Directive), the operating
capacity of relay outputs (A, B, C) should be 30VDC 0.3A.
*6. Terminals SD, SE and 5 are isolated from each other. Do not earth (ground).
Avoid connecting the terminal SD and 5 and the terminal SE and 5.
6
1.2 Main circuit terminals
r
y
1.2.1 Terminal block layout
zFR-F520J-0.4K, 0.75K
N/- P/+
P1
Jumpe
Main circuit terminals
zFR-F520J-1.5K, 2.2K, 3.7K
z
FR-F540J-0.4K, 0.75K, 1.5K, 2.2K, 3.7K
N/-
Jumper
P/+
R/L1 S/L2 T/L3
Power supply
U V W
IM
Motor
zFilter pack
zFR-F520J-5.5K, 7.5K, 11K, 15K
FR-BFP-(H)0.4K to (H)15K
zFR-F540J-5.5K, 7.5K, 11K, 15K
Jumper
P1
P/+
R/L1 S/L2
N/-
Power supply
T/L3
U V W
IM
Motor
zConnection of the inverter and filter pack
(For details, refer to the instruction manual (basic).)
Filter pack
(FR-BFP)
R0 S0 T0
Earth
(Ground)
Power supply
GND
P1
Power suppl
RST P1PGND
To the inverter
terminal block
Jumper
N/-
P/+
P1
P1 P R S T
R/L1 S/L2 T/L3
Inverter
(FR-F500J)
R/L1 S/L2
T/L3
U V W
IM
Motor
R0 S0 T0
Power
supply
U V W
IM
Motor
1
WIRING
CAUTION
•Make sure the power cables are connected to the R0, S0, T0 of the filter pack (FR-
BFP) (If using the inverter without filter pack, connect to the R, S, T of the
inverter). Never connect the power cable to the U, V, W of the inverter. (Phase
need not be matched)
•Connect the motor to U, V, W. At this time, turning on the forward rotation switch
(signal) rotates the motor in the counterclockwise direction when viewed from the
motor shaft.
•When connecting the filter pack, make sure the jumper across the terminals P1-P
of the inverter is removed.
7
Main circuit terminals
1.2.2 Cables, wiring length, and crimping terminals
The following table indicates a selection example for the wiring length of 20m.
<200V class>
2
)
Cable Sizes
AWG
R, S, T
U, V, W
Cable Sizes
AWG
PVC Cable
(mm2)
R, S, T U, V, W
PVC Cable
(mm2)
U, V, W
Ter-
Applicable
Inverter
FR-F520J-0.4K to
0.75K
FR-F520J-1.5K,
2.2K
FR-F520J-3.7K
FR-F520J-5.5K
FR-F520J-7.5K
FR-F520J-11K
FR-F520J-15K
Tight-
minal
ening
Screw
Torque
size
N
M3.5 1.2 2-3.5 2-3.5 2 2 14 14 2.5 2.5
M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
M4 1.5 5.5-4 5.5-4 3.5 3.5 12 12 4 2.5
M5 2.5 5.5-5 5.5-5 5.5 5.5 10 10 6 6
M5 2.5 14-5 8-5 14 8 6 8 16 10
M5 2.5 14-5 14-5 14 14 6 6 16 16
M6 4.4 22-6 22-6 22 22 4 4 25 25
Crimping
⋅
m
R, S, T U, V, W
Termin al
HIV Cable
(mm
R, S, T
U, V, W
<400V class>
Ter-
Applicable
Inverter
FR-F540J-0.4K to
3.7K
FR-F540J-5.5K
FR-F540J-7.5K
FR-F540J-11K
FR-F540J-15K
Tight-
minal
ening
Screw
Torque
size
N
M4 1.5 2-4 2-4 2 2 14 14 2.5 2.5
M4 1.5 5.5-4 2-4 3.5 2 12 14 4 2.5
M4 1.5 5.5-4 5.5-4 3.5 3.5 12 12 4 4
M4 1.5 5.5-4 5.5-4 5.5 5.5 10 10 6 6
M6 4.4 14-6 8-6 14 8 6 8 16 10
Crimping
Termin al
⋅
m
R, S, T U, V, W R, S, T U, V, W R, S, T U, V, W R, S, T
HIV Cable
(mm2)
*The terminal screw size of the filter pack (FR-BFP) is the same as that of the inverter.
Wiring length
• FR-F540J-0.4K ............................. 50m or less
• FR-F520J-0.4K to 3.7K
FR-F540J-0.75K to 3.7K ............... 100m or less
• FR-F520J-5.5K to 15K
FR-F540J-5.5K to 15K .................. 500m or less
CAUTION
•If the wiring length of the FR-F540J-0.4K or 0.75K is 30m or more, use the
carrier frequency of 1kHz.
•When automatic torque boost is selected in Pr. 98 "automatic torque boost
selection (motor capacity)", the wiring length must be 30m maximum. (Refer
to page 133.)
•If the wiring distance between the inverter and motor is long, the motor torque
will decrease due to the voltage drop of the main circuit cable (especially at
low-frequency output).
Use thick cables so that a voltage drop is 2% or less.
8
Main circuit terminals
1.2.3 Wiring instructions
1) Use crimping terminals with insulation sleeve to wire the power supply and motor.
2) Application of power to the output terminals (U, V, W) of the inverter will damage the
inverter. Never perform such wiring.
3) After wiring, wire offcuts must not be left in the inverter (filter pack).
Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter
clean.
When drilling mounting holes in an enclosure etc., take care not to allow chips and
other foreign matter to enter the inverter.
4) Use cables of the recommended size to make a voltage drop 2% maximum.
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.
5) For long distance wiring, the high response current limit function may be reduced or
the devices connected to the secondary side may malfunction or become faulty
under the influence of a charging current due to the stray capacity of wiring.
Therefore, note the maximum overall wiring length.
6) Electromagnetic wave interference
The input/output (main circuit) of the inverter includes high frequency components,
which may interfere with the communication devices (such as AM radios) used near
the inverter. When using the inverter without the filter pack, install a FR-BIF(-H)
optional radio noise filter (for use on the input side only) or FR-BSF01 or FR-BLF
line noise filter to minimize interference.
7) Do not install a power capacitor, surge suppressor or radio noise filter (FR-BIF(-H)
option) on the output side of the inverter.
This will cause the inverter to trip or the capacitor and surge suppressor to be
damaged. If any of the above devices are connected, remove them.
8) Before starting wiring or other work after the inverter is operated, wait for at least 10
minutes after the power supply has been switched off, and check that there are no
residual voltage using a tester or the like. The capacitor is charged with high
voltage for some time after power off and it is dangerous.
9
1
WIRING
Main circuit terminals
1.2.4 Selection of peripheral devices
Check the inverter type of the inverter you purchased. Appropriate peripheral devices
must be selected according to the capacity.
Refer to the following list and prepare appropriate peripheral devices:
<200V class>
Moulded Case Circuit Breaker
Motor
Output
Inverter Type
Earth Leakage Circuit Breaker (ELB)
(kW)
With filter pack Without filter pack
0.4 FR-F520J-0.4K
0.75 FR-F520J-0.75K
1.5 FR-F520J-1.5K 30AF/15A 30AF/15A S-N10
2.2 FR-F520J-2.2K
3.7 FR-F520J-3.7K
5.5 FR-F520J-5.5K 50AF/40A 50AF/50A S-N25
7.5 FR-F520J-7.5K
11 FR-F520J-11K
15 FR-F520J-15K 100AF/100A 225AF/125A S-N65
<400V class>
Motor
Output
Inverter Type
Earth Leakage Circuit Breaker (ELB)(*2,
(kW)
With filter pack Without filter pack
0.4 FR-F540J-0.4K
0.75 FR-F540J-0.75K
1.5 FR-F540J-1.5K 30AF/10A 30AF/10A S-N10
2.2 FR-F540J-2.2K
3.7 FR-F540J-3.7K
5.5 FR-F540J-5.5K 30AF/20A 30AF/30A S-N20, S-N21
7.5 FR-F540J-7.5K
11 FR-F540J-11K
15 FR-F540J-15K 50AF/50A 100AF/60A S-N35
(MCCB)(*1, *3) or
Magnetic
Contactor
(*2, *3)
30AF/5A 30AF/5A S-N10
30AF/10A 30AF/10A S-N10
30AF/15A 30AF/20A S-N10
30AF/30A 30AF/30A S-N20,S-N21
50AF/50A 100AF/60A S-N35
100AF/75A 100AF/75A S-N50
(MC)
Moulded Case Circuit Breaker
(MCCB)(*1, *3) or
Magnetic
Contactor
*3)
30AF/5A 30AF/5A S-N10
30AF/5A 30AF/5A S-N10
30AF/10A 30AF/15A S-N10
30AF/15A 30AF/20A S-N20, S-N21
30AF/30A 30AF/30A S-N20, S-N21
50AF/40A 50AF/50A S-N25
(MC)
• Select the MCCB according to the power supply
*1.
capacity.
• Install one MCCB per inverter.
MCCB
MCCB
INV
INV
IM
IM
*2. For installations in the United States or Canada, the
circuit breaker must be inverse time or instantaneous trip type.
*3. 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.
10
Main circuit terminals
1.2.5 Leakage current and installation of earth (ground) leakage circuit breaker
Due to static capacitances existing in the inverter I/O wiring and motor, leakage
currents flow through them. Since their values depend on the static capacitances,
carrier frequency, etc., take the following countermeasures.
(1) To-earth (ground) leakage currents
Leakage currents may flow not only into the inverter's own line but also into the
other line through the earth (ground) cable, etc.
These leakage currents may operate earth (ground) leakage circuit breakers and
earth (ground) leakage relays unnecessarily.
Countermeasures
• If the carrier frequency setting is high, decrease the carrier frequency (Pr. 72) of the
inverter.
Note that motor noise increases. Selection of Soft-PWM control (Pr. 70) will make it
unoffending. (Factory setting)
• By using earth leakage circuit breakers designed for harmonic and surge
suppression in the inverter's own line and other line, operation can be performed
with the carrier frequency kept high (with low noise).
REMARKS
When the filter pack is provided, leakage current can be reduced by removing the earth (ground)
cable for the capacitive filter and securing it with the supplied screw for leakage current
countermeasure (plastic) and spacer (plastic). However, the noise reduction effect of the
capacitive filter is lost.
(Pull out the earth (ground) cable for the capacitive filter a little to wire.)
<Mounting method>
Filter pack
Screw for leakage current countermeasure (plastic)
(Tightening torque is 0.35 0.05N m)
1
Spacer
(plastic)
Earth (Ground) cable for capacitive filter
CAUTION
If the earth (ground) cable for the capacitive filter is removed, it is charged
while power is on or shortly after power off. Do not touch the earth (ground)
cable as you may get an electric shock.
11
WIRING
Main circuit terminals
(2) Line-to-line leakage currents
Harmonics of
leakage currents
flowing in static
capacities between
Power
supply
MCCB
Inverter
the inverter output
cables may operate
the external thermal
Line-to-Line Leakage Current Path
relay unnecessarily.
Countermeasures
• Use the electronic thermal relay function of the inverter.
• Decrease the carrier frequency. Note that motor noise increases. Selection of
Soft-PWM (Pr. 70) makes it unoffending.
To ensure that the motor is protected against line-to-line leakage currents, it is
recommended to use a temperature sensor to directly detect motor temperature.
Installation and selection of moulded case circuit breaker
Install a moulded case circuit breaker (MCCB) on the power receiving side to
protect the wiring of the inverter primary side. Select the MCCB according to the
power supply side power factor (which depends on the power supply voltage, output
frequency and load). Especially for a completely electromagnetic MCCB, one of a
slightly large capacity must be selected since its operation characteristic varies with
harmonic currents. (Check it in the data of the corresponding breaker.) As an earth
(ground) leakage breaker, use the Mitsubishi earth (ground) leakage breaker
designed for harmonics and surge suppression. (Refer to page 10 for the
recommended models.)
Thermal relay
Line static
capacitances
Motor
IM
CAUTION
•Select the MCCB according to the inverter power supply capacity.
•Install one MCCB per inverter.
•The inverter has a protective function based on electronic overcurrent protection
(electronic thermal relay function) to protect the motor from overheating.
However, when running multiple motors with one inverter or operating a multipole motor, provide a thermal relay (OCR) between the inverter and motor. In this
case, set the electronic thermal relay function (electronic overcurrent protection)
of the inverter to 0A. And set the electronic overcurrent relay, add the line-to-line
leakage current to 1.0 times the current value at 50 Hz on the motor rating plate or
to 1.1 times the current value at 60 Hz.
•When the FR-BFP (filter pack) is used, leakage current is 4mA.(8mA for 400V
class.) (equivalent to one-phase of cable for the three-phase three wire
connection)
12
Main circuit terminals
)
(3) Selecting the rated sensitivity current for the earth leakage circuit
breaker
When using the earth leakage circuit breaker with the inverter circuit, select its rated
sensitivity current as follows, independently of the PWM carrier frequency:
• Breaker for harmonic and surge
Rated sensitivity current:
I
∆n ≥ 10 × (lg1+Ign+lg2+lgm)
• Standard breaker
Rated sensitivity current:
I
∆n ≥ 10 × {lg1+lgn+3 × (lg2+lgm)}
lg1, lg2 : Leakage currents of cable
path during commercial
power supply operation
lgn : Leakage current of noise
filter on inverter input side
lgm : Leakage current of motor
during commercial power
supply operation
<Example>
22
2mm ×5m
NV
Filter
pack
Example of leakage
current per 1km in cable
path during commercial
power supply operation
when the CV cable is
routed in metal conduit
(200V 60Hz)
120
100
80
60
40
20
0
2 3.5 8 142238 80
Leakage current (mA)
Cable size (mm)
2mm ×70m
Inverter
5.5 3060100
φ
3 200V
IM
1.5kW
Leakage current
example of three-phase
induction motor
during commercial
power supply
operation
(200V 60Hz)
2.0
1.0
0.7
0.5
0.3
0.2
150
2
0.1
Leakage current (mA)
Motor capacity (kW
1.5 3 .7
2.2
7.5 152 21137
5.5 18.5
55
45
30
Ig1 Ign Ig2 Igm
Leakage current (Ig1) (mA)
Breaker for Harmonic and
Surge
20 ×
1000m
5m
Standard Breaker
= 0.10
Leakage current (Ign) (mA) 0 (without filter pack)
Leakage current (Ig2) (mA)
Motor leakage
current (Igm) (mA)
20 ×
70m
1000m
0.16
= 1.40
Total leakage current (mA) 1.66 4.78
Rated sensitivity current
(mA) (≥ Ig
× 10)
30 100
13
1
WIRING
Main circuit terminals
CAUTION
•The earth (ground) leakage circuit breaker should be installed to the primary
(power supply) side of the inverter.
•In the connection neutral point earth (grounded) system, the sensitivity
current becomes worse for earth (ground) faults on the inverter secondary
side. 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)
•When the breaker is installed on the secondary side of the inverter, it may be
unnecessarily operated by harmonics if the effective value is less than the
rating. In this case, do not install the breaker since the eddy current and
hysteresis loss increase and the temperature rises.
•General products indicate the following models: BV-C1, BC-V, NVB, NV-L, NVG2N, NV-G3NA, NV-2F, earth (ground) leakage relay (except NV-ZHA), NV with
AA neutral wire open-phase protection
The other models are designed for harmonic and surge suppression: NV-C/
NV-S/MN series, NV30-FA, NV50-FA, BV-C2, earth (ground) leakage alarm
breaker (NF-Z), NV-ZHA, NV-H
14
Main circuit terminals
r
1.2.6 Power-off and magnetic contactor (MC)
(1) Inverter input side magnetic contactor (MC)
On the inverter's input side, it is recommended to provide an MC for the following
purposes. (Refer to page 10 for selection)
1) To release the inverter from the power supply when the inverter protective function
is activated or the drive becomes faulty (e.g. emergency stop operation)
2) To prevent any accident due to an automatic restart at restoration of power after an
inverter stop made by a power failure
3) To rest the inverter for an extended period of time
The control power supply for inverter is always running and consumes a little power.
When stopping the inverter for an extended period of time, powering off the inverter
will save power slightly.
4) To separate the inverter from the power supply to ensure safe maintenance and
inspection work
The inverter's input side MC is used for the above purpose, select class JEM1038AC3 for the inverter input side current when making an emergency stop during
normal operation.
REMARKS
The MC may be switched on/off to start/stop the inverter. However, since repeated inrush
currents at power on will shorten the life of the converter circuit (switching life is about 100,000
times), frequent starts and stops must be avoided. Turn on/off the inverter start controlling
terminals (STF, STR) to run/stop the inverter.
As shown on the right,
always use the start signal
(ON or OFF across
terminals STF or STR-SD)
Power
supply
to make a start or stop.
(Refer to page 28)
*1. When the power supply
is 400V class, install a
step-down transformer.
(2) Handling of output side magnetic contactor
In principle, do not provide a magnetic contactor between the inverter and motor and
switch it from off to on during operation. If it is switched on during inverter operation, a
large inrush current may flow, stopping the inverter due to overcurrent shut-off. When
an MC is provided for switching to the commercial power supply, for example, switch it
on/off after the inverter and motor have stopped.
MCCB
Operation ready
ON
OFF
MC
Start/Stop
OFF
Operation
RA
MC
Inverter Start/Stop Circuit Example
MC
R0
S0
T0
T (*1)
MC
RA
(with filter pack)
R
S
T
P1
P
RA
R
S
T
P1
P
Inverter
STF(STR)
SD
W
U
To
V
moto
A
B
C
1
WIRING
15
Main circuit terminals
1.2.7 Regarding the installation of the reactor
When the inverter is installed near a large-capacity power transformer (500kVA or
more with the wiring length of 10m (32.81feet) or less) or the power capacitor is to be
switched, an excessive peak current will flow in the power supply input circuit,
damaging the converter circuit. In such a case, always install the reactor (FR-HEL(-H)
/FR-BEL(-H) or FR-HAL(-H)/FR-BAL(-H)). Since the filter pack includes a power factor
improving DC reactor, a reactor need not be installed separately.
Power
supply
MCCB
FR-HAL(-H)/
FR-BAL(-H)
R
S
TZ
Inverter
X
R
Y
S
T
P
FR-HEL(-H)/
FR-BEL(-H)(*)
P1
W
1500
U
V
1000
Power supply equipment
capacity (kVA)
Reactor installation
range
500
010
Wiring length (m)
REMARKS
*When connecting the FR-HEL(-H)/FR-BEL(-H) (filter pack), remove the jumper across
terminals P-P1.
The wiring length between the FR-HEL(-H)/FR-BEL(-H) and the inverter should be 5m
maximum and as short as possible.
Use the cables which are equal in size to those of the main circuit. (Refer to page 8)
CAUTION
•The power factor improving capacitor and surge suppressor on the inverter
output side may be overheated or damaged by the high frequency
components of the inverter output. Also, since an excessive current flows in
the inverter to activate overcurrent protection, do not install a capacitor or
surge suppressor. Use a power factor improving reactor for power factor
improvement.
•If a surge voltage occurs in the power supply system, this surge energy may
flow into the inverter, causing the inverter to display OV1, OV2 or OV3 and
come to an alarm stop. In such a case, also install the optional FR-HEL(-H)/FRBEL(-H) or FR-HAL(-H)/FR-BAL(-H) power factor improving reactor.
16
Main circuit terminals
1.2.8
Regarding noise (EMI) and the installation of a noise filter
Some noise enters the inverter causing it to malfunction and others are generated by
the inverter causing the malfunction of peripheral devices. Though the inverter is
designed to have high immunity performance, it handles low-level signals, so it
requires the following general countermeasures to be taken.
(1) General countermeasures
• Do not run the power cables (I/O cables) and signal cables of the inverter in parallel
with each other and do not bundle them.
• Use twisted shield cables for the detector connecting and control signal cables and
connect the sheathes of the shield cables to terminal SD.
• Earth (Ground) the inverter, motor, etc. at one point.
• Capacitances exist between the inverter's I/O wiring, other cables, earth (ground)
and motor, through which leakage currents flow to cause the earth leakage circuit
breaker, earth (ground) leakage relay and external thermal relay to operate
unnecessarily. To prevent this, take appropriate measures, e.g. set the carrier
frequency in Pr. 72 to a low value, use an earth (ground) leakage circuit breaker
designed for suppression of harmonics and surges, and use the electronic thermal
relay function built in the inverter.
• The input and output of the inverter main circuit include high-degree harmonics,
which may disturb communication devices (AM radios) and sensors used near the
inverter.
<Noise (EMI) reduction examples>
Inverter
power supply
Separate inverter and power
line by more than 30cm
and at least 10cm
from sensor circuit.
Control
power supply
Do not earth (ground)
enclosure directly.
Do not earth (ground)
control cable.
Enclosure
Filter
pack
Power
supply
for sensor
Reduce carrier
frequency.
Inverter
FRBLF
Do not earth (ground) shield but connect
it to signal common cable.
Install a line noise filter
on inverter's output side.
Use 4-core cable for motor
power cable and use one
cable as earth (ground) cable.
Use twisted pair shielded cable.
Sensor
FR-BLF
FR-BSF01
IM
Motor
1
WIRING
REMARKS
For the inverter without filter pack, install a line noise filter (FR-BLF, FR-BSF01) or radio noise
filter (FR-BIF) on the inverter input side as a noise reduction measure.
CAUTION
For compliance with the EU, EMC directive, please refer the instruction manual (basic).
17
Main circuit terminals
1.2.9 Earthing (Grounding) precautions
z Leakage currents flow in the inverter (filter pack). To prevent an electric shock, the
inverter (filter pack) and motor 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)
z Use the dedicated earth (ground) terminal to earth (ground) the inverter (filter pack).
(Do not use the screw in the casing, chassis, etc.)
Use a tinned* crimping terminal to connect the earth (ground) cable. When
tightening the screw, be careful not to damage the threads.
*Plating should not include zinc.
z Use the thickest possible earth (ground) cable. Use the cable whose size is equal to
or greater than that indicated in the following table, and minimize the cable length.
The earthing (grounding) point should be as near as possible to the inverter.
2
Motor Capacity
2.2kW or less 2 (2.5) 2 (2.5)
3.7kW 3.5 (4) 2 (4)
5.5kW 5.5 (6) 3.5 (4)
7.5kW 14 (16) 3.5 (4)
11kW 14 (16) 5.5 (6)
15kW 22 (25) 14 (16)
Earth (Ground) Cable Size (Unit: mm
200V class 400V class
For use as a product compliant with the Low Voltage Directive, use PVC cable
whose size is indicated within parentheses.
)
z As a noise reduction technique, use one wire of the four-core cable with the earth
(ground) terminal of the motor, and earth (ground) at one point from the filter pack
side via the inverter. (Refer to page 2.)
Inverter
R
S
T
P1
P
W
U
V
Motor
IM
Power
supply
Earthing
(Grounding)
Filter pack
R
R0
S
S0
T
T0
P1
P
GND
(For the type without filter pack, earth (ground) the motor with the inverter at one point
on the inverter side.)
CAUTION
When the inverter is run in the low acoustic noise mode, more leakage currents
occur than in the non-low acoustic noise mode due to high-speed switching
operation. Always earth (ground) the inverter, motor and filter pack before use.
18
Main circuit terminals
1.2.10 Power supply harmonics
The inverter may generate power supply harmonics from its converter circuit to affect
the power generator, power capacitor etc. Power supply harmonics are different from
noise and leakage currents in source, frequency band and transmission path. Take the
following countermeasure suppression techniques.
The following table indicates differences between harmonics and noise:
Item Harmonics Noise
Frequency
Environment To-electric channel, power impedance To-space, distance, wiring path
Quantitative
understanding
Generated amount Nearly proportional to load capacity
Affected equipment
immunity
Suppression example Provide reactor.* Increase distance.
*The filter pack (FR-BFP) produces the same effect as when the DC reactor (FR-
HEL(-H)/FR-BEL(-H)) is connected.
Suppression technique
Harmonic currents produced
on the power supply side by
the inverter change with such
conditions as whether there
are wiring impedances and a
DC reactor (FR-HEL(-H)/FRBEL(-H) or FR-HAL(-H)/FRBAL(-H)) and the magnitudes
of output frequency and
output current on the load
side.
For the output frequency and output current, we understand that they should be
calculated in the conditions under the rated load at the maximum operating frequency.
CAUTION
The power factor improving capacitor and surge suppressor on the inverter
output side may be overheated or damaged by the high frequency components
of the inverter output. Also, since an excessive current flows in the inverter to
activate overcurrent protection, do not provide a capacitor and surge
suppressor on the inverter output side when the motor is driven by the inverter.
To improve the power factor, insert a reactor on the inverter's primary side or
DC circuit. For full information, refer to page 16.
Normally 40th to 50th degrees or less
(up to 3kHz or less)
Theoretical calculation possible
Specified in standard per equipment
FR-HEL(-H)
/FR-BEL(-H)
MCCB
FR-HAL(-H)
/FR-BAL(-H)
High frequency (several 10kHz
to 1GHz order)
Random occurrence,
quantitative grasping difficult
Change with current variation
ratio (larger as switching speed
increases)
Different depending on maker's
equipment specifications
Motor
IM
Inverter
Do not provide power factor
improving capacitor.
1
WIRING
19
Main circuit terminals
1.2.11 Harmonic suppression guideline
Harmonic currents flow from the inverter to a power receiving point via a power
transformer. The harmonic suppression guideline was established to protect other
consumers from these outgoing harmonic current.
The three-phase 200V input specifications 3.7kW or less are previously covered by
"Harmonic suppression guideline for household appliances and general-purpose
products" and other models are covered by "Harmonic suppression guideline for
consumers who receive high voltage or special high voltage". However, the generalpurpose inverter has been excluded from the target products covered by "Harmonic
suppression guideline for household appliances and general-purpose products" in
January 2004. Later, this guideline was repealed on September 6, 2004. All capacities
of all models are now target products of "Harmonic suppression guideline for
consumers who receive high voltage or special high voltage" (hereinafter referred to
as "Guideline for specific consumers").
"Guideline for specific consumers"
This guideline sets forth the maximum values of harmonic currents outgoing from a
high-voltage or especially high-voltage consumer who will install, add or renew
harmonic generating equipment. If any of the maximum values is exceeded, this
guideline requires that consumer to take certain suppression measures.
Table 1 Maximum Values of Outgoing Harmonic Currents per 1kW Contract Power
Received Power Voltage 5th 7th 11th 13th 17th 19th 23rd
6.6 kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70
22 kV 1.8 1.3 0.82 0.69 0.53 0.47 0.39 0.36
33 kV 1.2 0.86 0.55 0.46 0.35 0.32 0.26 0.24
Over
23rd
20
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