Mitsubishi FR - S500 User Manual

T R A N S I S T O R I Z E

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I N S T R U C T I O N M

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Thank you for choosing this Mitsubishi Transistorized inverter.

This instruction manual (detailed) provides instructions for advanced use of the FR-S500 series inverters.

Incorrect handling might cause an unexpected fault. Before using the inverter, always read this instruction manual and the instruction manual (basic) [IB-0600026] packed with the product carefully to use the equipment to its optimum.

This instruction manual uses the International System of Units (SI). The measuring units in the yard and pound system are indicated in parentheses as reference values.

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have
read through the instruction manual (basic) and appended documents carefully and
can use the equipment correctly. Do not use the inverter until you have a full
knowledge of the equipment, safety information and instructions.
In this instruction manual, the safety instruction levels are classified into
"WARNING" and "CAUTION".
	WARNING	Assumes that incorrect handling may cause hazardous
		conditions, resulting in death or severe injury.
		Assumes that incorrect handling may cause hazardous
	CAUTION
		conditions, resulting in medium or slight injury, or may
		cause physical damage only.
Note that even the CAUTION level may lead to a serious consequence according to
conditions. Please follow the instructions of both levels because they are important
to personnel safety.
1. Electric Shock Prevention

WARNING

While power is on or when the inverter is running, do not open the front cover. You may get an electric shock.

Do not run the inverter with the front cover removed. Otherwise, you may access the exposed high-voltage terminals or the charging part of the circuitry and get an electric shock.

If power is off, do not remove the front cover except for wiring or periodic inspection. You may access the charged inverter circuits and get an electric shock.

Before starting wiring or inspection, check for residual voltages with a meter etc. more than 10 minutes after power-off.

Earth the inverter.

Any person who is involved in wiring or inspection of this equipment should be fully competent to do the work.

Always install the inverter before wiring. Otherwise, you may get an electric shock or be injured.

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

Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Otherwise, you may get an electric shock.

Do not change the cooling fan while power is on.

It is dangerous to change the cooling fan while power is on.

When you have removed the front cover, do not touch the connector above the 3-digit monitor LED display. You will get an electric shock.

A-1

2. Fire Prevention

CAUTION

Mount the inverter to incombustible material. Mounting it to or near combustible material can cause a fire.

If the inverter has become faulty, switch off the inverter power. A continuous flow of large current could cause a fire.

Do not connect a resistor directly to the DC terminals P(+ ), N(− ). This could cause a fire.

3. Injury Prevention

CAUTION

Apply only the voltage specified in the instruction manual to each terminal to prevent damage etc.

Ensure that the cables are connected to the correct terminals. Otherwise, damage etc. may occur.

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

While power is on and for some time after power-off, do not touch the inverter or brake resistor as they are hot and you may get burnt.

4. Additional instructions

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

(1) Transportation and installation

CAUTION

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

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

Ensure that installation position and material can withstand the weight of the inverter. Install according to the information in the Instruction Manual.

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

When carrying the inverter, do not hold it by the front cover or setting dial; it may fall off or fail.

Do not stand or rest heavy objects on the inverter.

Check the inverter mounting orientation is correct.

Prevent screws, wire fragments, other conductive bodies, oil or other flammable substances from entering the inverter.

Do not drop the inverter, or subject it to impact.

Use the inverter under the following environmental conditions:

		Ambient	-10° C to +50° C (14° F to 122° F) (non-freezing)
		temperature
		Ambient humidity	90%RH or less (non-condensing)
	Environment	Storage	-20° C to +65° C * (-4° F to 149° F)
		temperature
		Ambience	Indoors (free from corrosive gas, flammable gas,
			oil mist, dust and dirt)
			Maximum 1000m (3280.80feet) above sea level for
			standard operation. After that derate by 3% for
		Altitude, vibration	every extra 500m (1640.40feet) up to 2500m
			(8202.00feet) (91%).
			5.9m/s2 or less (conforming to JIS C 0040)
	*Temperatures applicable for a short time, e.g. in transit.
			A-2

(2) Wiring

CAUTION

Do not fit capacitive equipment such as power factor correction capacitor, radio noise filter or surge suppressor to the output of the inverter.

The connection orientation of the output cables U, V, W to the motor will affect the direction of rotation of the motor.

(3) Trial run

CAUTION

Check all parameters, and ensure that the machine will not be damaged by a sudden start-up.

When the load GD2 is small (at the motor GD2 or smaller) for 400V from 1.5K to 3.7K, the output current may vary when the output frequency is in the 20Hz to 30Hz range.

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

When setting the PWM to a higher frequency, check for noise or leakage current problem and take countermeasures against it.

(4) Operation

WARNING

When you have chosen the retry function, stay away from the equipment as it will restart suddenly after an alarm stop.

The [STOP] key is valid only when the appropriate function setting has been made. Prepare an emergency stop switch separately.

Make sure that the start signal is off before resetting the inverter alarm. A failure to do so may restart the motor suddenly.

The load used should be a three-phase induction motor only. Connection of any other electrical equipment to the inverter output may damage the equipment. Do not modify the equipment.

CAUTION

The electronic overcurrent protection does not guarantee protection of the motor from overheating.

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

Use a noise filter to reduce the effect of electromagnetic interference. Otherwise nearby electronic equipment may be affected.

Take measures to suppress harmonics. Otherwise power harmonics from the inverter may heat/damage the power capacitor and generator.

When a 400V class motor is inverter-driven, it should be insulation-enhanced or surge voltages suppressed. Surge voltages attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor.

When parameter clear or all clear is performed, each parameter returns to the factory setting. Re-set the required parameters before starting operation.

The inverter can be easily set for high-speed operation. Before changing its setting, fully examine the performances of the motor and machine.

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

Before running an inverter which had been stored for a long period, always perform inspection and test operation.

A-3

(6) Maintenance, inspection and parts replacement

CAUTION

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

(7) Disposing of the inverter

CAUTION

Treat as industrial waste.

(8) General instructions

Many of the diagrams and drawings in this instruction manual show the inverter without a cover, or partially open. Never operate the inverter like this. Always replace the cover and follow this instruction manual when operating the inverter.

A-4

CONTENTS
1. WIRING	1
1.1 Japanese Version.....................................................................................	2
1.1.1 Terminal connection diagram ....................................................................	2
1.1.2 Layout and wiring of main circuit terminals...............................................	3
1.2 North America Version .............................................................................	4
1.2.1 Terminal connection diagram ....................................................................	4
1.2.2 Layout and wiring of main circuit terminals...............................................	5
1.3 European Version.....................................................................................	7
1.3.1 Terminal connection diagram ....................................................................	7
1.3.2 Layout and wiring of main circuit terminals...............................................	8
1.4 Description of I/O Terminal Specifications ...............................................	9
1.4.1 Main circuit ..................................................................................................	9
1.4.2 Control circuit ..............................................................................................	9
1.5 How to Use the Main Circuit Terminals..................................................	11
1.5.1 Cables, wiring lengths, crimping terminals, etc. .....................................	11
1.5.2 Wiring instructions ....................................................................................	12
1.5.3 Peripheral devices ....................................................................................	13
1.5.4 Leakage current and installation of earth leakage circuit breaker......	15
1.5.5 Power-off and magnetic contactor (MC) .................................................	17
1.5.6 Regarding the installation of the power factor improving reactor .......	18
1.5.7 Regarding noise and the installation of a noise filter..............................	18
1.5.8 Grounding precautions.............................................................................	19
1.5.9 Regarding power harmonics.....................................................................	20
1.5.10 Japanese power harmonic suppression guideline...............................	20
1.6 How to Use the Control Circuit Terminals ..............................................	24
1.6.1 Terminal block layout................................................................................	24
1.6.2 Wiring instructions ....................................................................................	24
1.6.3 Changing the control logic........................................................................	25
1.7 Input Terminals.......................................................................................	28
1.7.1 Run (start) and stop (STF, STR, STOP).................................................	28
1.7.2 Connection of frequency setting potentiometer and output frequency
meter (10, 2, 5, 4, AU)..............................................................................	31
1.7.3 External frequency selection (REX, RH, RM, RL)..................................	32
1.7.4 Indicator connection and adjustment ......................................................	34
1.7.5 Control circuit common terminals (SD, 5, SE)........................................	37
1.7.6 Signal inputs by contactless switches.....................................................	37
1.8 How to Use the Input Signals
(Assigned Terminals RL, RM, RH, STR)................................................	38
1.8.1 Multi-speed setting (RL, RM, RH, REX signals): Setting "0, 1, 2, 8"
Remote setting (RL, RM, RH signals): Setting "0, 1, 2".........................	38
1.8.2 Second function selection (RT signal): Setting "3".................................	38
I

Contents

1.8.3 Current input selection "AU signal": Setting "4"......................................			38
1.8.4 Start self-holding selection (STOP signal): Setting "5"...........................			38
1.8.5 Output shut-off (MRS signal): Setting "6"................................................			39
1.8.6 External thermal relay input: Setting "7"..................................................			39
1.8.7 Jog operation (JOG signal): Setting "9" ..................................................			40
1.8.8 Reset signal: Setting "10".........................................................................			40
1.8.9 PID control valid terminal: Setting "14"....................................................			41
1.8.10 PU operation/external operation switching: Setting "16" .....................			41
1.9 Handling of the RS-485 Connector
(Type with RS-485 Communication Function) .......................................			41
1.10 Design Information ...............................................................................			44
2. FUNCTIONS			45
2.1 Function (Parameter) List.......................................................................			46
2.2 List of Parameters Classified by Purpose of Use...................................			56
2.3 Explanation of Functions (Parameters)..................................................			58
2.3.1 Torque boost	...........................................................................		58
2.3.2 Maximum and minimum frequency .......................................			59
2.3.3 Base frequency, Base frequency voltage ....................			59
2.3.4 Multi-speed operation	to	to	....... 61
2.3.5 Acceleration/deceleration time		...................	62
2.3.6 Electronic overcurrent protection ....................................................			64
2.3.7 DC injection brake	.........................................................		64
2.3.8 Starting frequency	...........................................................................		65
2.3.9 Load pattern selection	.....................................................................		66
2.3.10 Jog frequency	.......................................................................		67
2.3.11 RUN key rotation direction selection .............................................			67
2.3.12 Stall prevention function and current limit function ......................			68
2.3.13 Stall prevention	............................................................		69
2.3.14 Acceleration/deceleration pattern .................................................			71
2.3.15 Extended function display selection .............................................			72
2.3.16 Frequency jump	to ...............................................................		72
2.3.17 Speed display ................................................................................			73
2.3.18 Biases and gains of the frequency setting voltage (current)
to	..........................................................................		74
2.3.19 Start-time ground fault detection selection ..................................			78
2.4 Output Terminal Function Parameters...................................................			78
2.4.1 Up-to-frequency sensitivity ..............................................................			78
2.4.2 Output frequency detection ....................................................			79
2.5 Current Detection Function Parameters.................................................			80
2.5.1 Output current detection functions ........................................			80
2.5.2 Zero current detection	............................................................		81
2.6 Display Function Parameters .................................................................			82
2.6.1 Monitor display	........................................................................		82
	II

2.6.2 Setting dial function selection																						.........................................................																					83
2.6.3 Monitoring reference																		..............................................................																									84
2.7 Restart Operation Parameters ...............................................................																																											84
2.7.1 Restart setting											.........................................................................																																84
2.8 Additional Function Parameters .............................................................																																											86
2.8.1 Remote setting function selection																													..................................................														86
2.9 Terminal Function Selection Parameters																																											88
2.9.1 Input terminal function selection																																										..........................	88
2.9.2 Output terminal function selection																																				.........................................							90
2.10 Operation Selection Function Parameters ...........................................																																											91
2.10.1 Retry function																										.....................................................																	91
2.10.2 PWM carrier frequency																								........................................................																			92
2.10.3 Applied motor						.................................................................................																																					93
2.10.4 Voltage input selection															..................................................................																												93
2.10.5 Input filter time constant																	................................................................																										94
2.10.6 Reset selection/PU stop selection																															................................................												94
2.10.7 Cooling fan operation selection																											....................................................																96
2.10.8 Parameter write inhibit selection																													..................................................														97
2.10.9 Reverse rotation prevention selection																																											98
																																		..........................................
2.10.10 Operation mode selection																				...........................................................																							98
2.10.11 PID control				to									....................................................................																														101
2.11 Auxiliary Function Parameters ...........................................................																																											109
2.11.1 Slip compensation																									.....................................................																		109
2.11.2 Automatic torque boost selection																														...............................................													109
2.11.3 Motor primary resistance																		............................................................																									111
2.12 Calibration Parameters ......................................................................																																											111
2.12.1 Meter (frequency meter) calibration																																(Japanese version).........											111
2.12.2 Meter (frequency meter) calibration																																(NA and EC version) ......											113
...............................................................................2.13 Clear Parameters																																											115
2.13.1 Parameter clear								...........................................................................																																			115
2.13.2 Alarm history clear											.......................................................................																																115
2.14 Communication Parameters
(Only for the type having the RS-485 communication function)...........																																											116
2.14.1 Communication settings																		to										,									...................................... 118
2.14.2 Operation and speed command write																																											130
																																								...............................
2.14.3 Link start mode selection																		............................................................																									131
2.14.4 E2PROM write selection																	..............................................................																										132
2.15 Parameter Unit (FR-PU04) Setting ....................................................																																											133
2.15.1 Parameter unit display language switching																																								...............................			133
2.15.2 Buzzer sound control														..................................................................																													133
2.15.3 PU contrast adjustment																...............................................................																											134
2.15.4 PU main display screen data selection																																						......................................					134
2.15.5 PU disconnection detection/PU setting lock																																									..............................		135

III

Contents

3. PROTECTIVE FUNCTIONS		136
3.1	Errors (Alarms) .....................................................................................	137
3.1.1 Error (alarm) definitions..........................................................................		137
3.1.2 To know the operating status at the occurrence of alarm
	(Only when FR-PU04 is used)...............................................................	145
3.1.3 Correspondence between digital and actual characters......................		145
3.1.4 Resetting the inverter .............................................................................		145
3.2	Troubleshooting....................................................................................	146
3.2.1 Motor remains stopped ..........................................................................		146
3.2.2 Motor rotates in opposite direction ........................................................		147
3.2.3 Speed greatly differs from the setting....................................................		147
3.2.4 Acceleration/deceleration is not smooth ...............................................		147
3.2.5 Motor current is large..............................................................................		147
3.2.6 Speed does not increase .......................................................................		147
3.2.7 Speed varies during operation...............................................................		147
3.2.8 Operation mode is not changed properly..............................................		148
3.2.9 Operation panel display is not operating...............................................		148
3.2.10 Parameter write cannot be performed ................................................		148
3.2.11 Motor produces annoying sound.........................................................		148
3.3	Precautions for Maintenance and Inspection.......................................	149
3.3.1 Precautions for maintenance and inspection........................................		149
3.3.2 Check items ............................................................................................		149
3.3.3 Periodic inspection..................................................................................		149
3.3.4 Insulation resistance test using megger................................................		150
3.3.5 Pressure test...........................................................................................		150
3.3.6 Daily and periodic inspection .................................................................		150
3.3.7 Replacement of parts .............................................................................		154
3.3.8 Measurement of main circuit voltages, currents and powers..............		157
4. SPECIFICATIONS		160
4.1	Specification List ..................................................................................	161
4.1.1 Ratings ....................................................................................................		161
4.1.2 Common specifications..........................................................................		165
4.2	Outline Drawings ..................................................................................	167
5. INSTRUCTIONS		170
5.1	Selecting Instructions ...........................................................................	171
5.2	Peripheral Selecting Instructions..........................................................	171
5.3	Operating Instructions ..........................................................................	173
5.4	Inverter-driven 400V class motor .........................................................	175
APPENDIX		176
APPENDIX 1 PARAMETER DATA CODE LIST ........................................		177

IV

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 Japanese Version ......................................................		2
1.2	North America Version...............................................	4
1.3 European Version ......................................................		7
1.4	Description of I/O Terminal specification ....................	9
1.5	How to Use the Main Circuit Terminals ....................	11
1.6	How to Use the Control Circuit Terminals ................	24
1.7	Input Terminals ........................................................	28
1.8	How to Use the Input Signals
	(Assigned Terminals RL, RM, RH, STR) ..................	38
1.9	Handling of the RS-485 Connector
	(Type with RS-485 Communication Function) ..........	41
1.10 Design Information.................................................		44
<Abbreviations>
	PU
	Control panel and parameter unit (FR-PU04)
	Inverter
	Mitsubishi transistorized inverter FR-S500 series
	FR-S500
	Mitsubishi transistorized inverter FR-S500 series
	Pr.
	Parameter number

1

Chapter1

Chapter 2

Chapter 3

Chapter 4

1.1 Japanese Version

1.1.1 Terminal connection diagram

FR-S520-0.1K to 3.7K (-R) (-C)

FR-S540-0.4K to 3.7K (-R)

		NFB MC		Inverter
	3-phase AC		R	U
	power supply		S	V
			T	W
	External transistor common
				P1
		24VDC power supply	PC
	Contact input common (source)
		Be careful not to short		P
		terminals PC-SD.
				N
		Forward rotation start	STF

Motor

IM

Ground

Power factor improving

DC reactor (FR-BEL: Option)

Jumper: Remove this jumper when FR-BEL is connected.

Reverse rotation start			STR *5		*6	A
		High	RH	*5	*6	B	Alarm
Multi-speed selection Middle			RM	*5	*6	C	output
		Low	RL	*5	*6RUN		Running		Operation status
Contact input common			SD						output
						SE	Open collector
									Open
			(Note)
Control input signals				SINK			output common		collector
									outputs
(No voltage input allowed)
					(*3)
Frequency setting signals (Analog)			SOURCE				Indicator
							1mA full-scale
Frequency		3 2	10 (+5V)				Analog meter
					Selected		(Digital indicator)
setting			2 DC 0 to 5V					1mA
potentiometer		1	DC 0 to 10V			FM
1/2W1k			5 (Common)					(+)	(-)
							Calibration
(*4)	Current input (-)
							resistor (*2)
4 to 20mADC (+)			4 (4 to 20mADC)
						SD

When using the current input as
the frequency setting signal, set
"4" in any of Pr. 60 to Pr. 63 (input
		RS-485 Connector (*1)
terminal function selection), assign
AU (current input selection) to any					Earth (Ground)
of terminals RH, RM, RL and STR,
and turn on the AU signal.

Main circuit terminal Control circuit input terminal Control circuit output terminal

REMARKS

*1 Only the type with RS-485 communication function.

*2 Not needed when the setting dial is used for calibration. This resistor is used when calibration must be made near the frequency meter for such a reason as a remote frequency meter. Note that the needle of the frequency meter may not deflect to full-scale when the calibration resistor is connected. In this case, use both the resistor and setting dial for calibration.

*3 You can switch between the sink and source logic positions. Refer to page 25. *4 When the setting potentiometer is used frequently, use a 2W1kΩ potentiometer. *5 The terminal functions change with input terminal function selection (Pr. 60 to

Pr. 63). (Refer to page 38, 88) (RES, RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, X14, X16, (STR) signal selection)

*6 The terminal functions change with output terminal function selection (Pr. 64, Pr. 65). (Refer to page 90) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, LF, ABC signal selection)

2

CAUTION

To prevent a malfunction due to noise, keep the signal cables more than 10cm (3.94inches) away from the power cables.

FR-S520S-0.1K to 1.5K (-R) (-C)

FR-S510W-0.1K to 0.75K (-R)

NFB MC

Motor

Power supply

R

U

S

V

IM

W

Earth

(Ground)

REMARKS

•To ensure safety, connect the power input to the inverter via a magnetic contactor and earth leakage circuit breaker or no-fuse breaker, and use the magnetic contactor to switch power on-off.

•The output is three-phase 200V.

1.1.2 Layout and wiring of main circuit terminals

FR-S520-0.1K, 0.2K, 0.4K, 0.75K (-R) (-C) FR-S520-1.5K, 2.2K, 3.7K (-R) (-C) FR-S540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K (-R)

				Jumper		Jumper
					N	P
			N	P1	P	P1
						R	S	T	U	V	W
R	S	T	U	V	W
										IM

IM

Power supply Motor Power supply Motor

FR-S520S-0.1K, 0.2K, 0.4K, 0.75K (-R) FR-S520S-1.5K (-R)

			Jumper		Jumper
				N	P
		N	P1	P	P1
					R	S	U	V	W
R	S	U	V	W

						IM	1
		IM
				Power supply Motor
Power supply Motor
FR-S510W-0.1K, 0.2K, 0.4K (-R)				FR-S510W-0.75K (-R)

		N		P	N	P
R	S	U	V	W
						R	S	U	V	W
			IM

Power supply		Motor		IM
		Power supply		Motor

CAUTION

•The power supply cables must be connected to R, S, T. If they are connected to U, V, W, the inverter will be damaged. (Phase sequence need not be matched.)

For use with a single-phase power supply, the power supply cables must be connected to R and S.

•Connect the motor to U, V, W.

Turning on the forward rotation switch (signal) at this time rotates the motor counterclockwise when viewed from the load shaft.

3

1.2 North America Version

1.2.1 Terminal connection diagram

FR-S520-0.1K to 3.7K-NA

FR-S540-0.4K to 3.7K-NA (R)

Inverter

NFB MC

3-phase AC R

power supply S T

External transistor common 24VDC power supply PC

Contact input common (source)

Take care not to short terminals PC-SD.

Forward rotation start STF

U

V

W

P1

P

N

Motor

IM

Earth

(Ground)

Power factor improving DC reactor

(FR-BEL: Option)

Jumper: Remove this jumper when FR-BEL is connected.

Reverse rotation start

STR *4

*5

A

High

RH

*4

*5

B

Alarm

Multi-speed selection Middle

RM

*4

*5

C

output

Low

RL

*4

*5RUN

Running

Operation status

Contact input common

SD

output

SE

Open collector

Open

Control input signals

output common

collector

(No voltage input allowed)

SINK

outputs

(*2)

Frequency setting signals (Analog)

SOURCE

Frequency

3

2

10 (+5V)

setting

DC 0 to 5V

potentiometer

2 DC 0 to 10V Selected

1

1/2W1k

5 (Common)

(*3)

Current input (-)

AM

(+) Analog signal

4 to 20mADC (+)

4 (4 to 20mADC)

output

When using the current input as the frequency setting signal, set "4" in any of Pr. 60 to Pr. 63 (input terminal function selection), assign AU (current input selection) to any of terminals RH, RM, RL and STR, and turn on the AU signal.

5(-) (0 to 5VDC)

RS-485 Connector (*1)

Earth (Ground)

Main circuit terminal Control circuit input terminal Control circuit output terminal

REMARKS

*1 Only the type with RS-485 communication function.

*2 You can switch between the sink and source logic positions. Refer to page 25. *3 When the setting potentiometer is used frequently, use a 2W 1kΩ potentiometer. *4 The terminal functions change with input terminal function selection (Pr. 60 to

Pr. 63). (Refer to page 38, 88) (RES, RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, X14, X16, (STR) signal selection)

*5 The terminal functions change with output terminal function selection (Pr. 64, Pr. 65). (Refer to page 90) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, LF, ABC signal selection)

4

NOTE

To prevent a malfunction due to noise, keep the signal cables more than 10cm (3.94inches) away from the power cables.

FR-S510W-0.1K to 0.75K-NA

NFB MC

Motor

Power supply

R

U

S

V

IM

W

Earth

(Ground)

REMARKS

•To ensure safety, connect the power input to the inverter via a magnetic contactor and earth leakage circuit breaker or no-fuse breaker, and use the magnetic contactor to switch power on-off.

•The output is three-phase 200V.

1.2.2 Layout and wiring of main circuit terminals

	FR-S520-0.1K, 0.2K, 0.4K, 0.75K-NA	FR-S520-1.5K, 2.2K, 3.7K-NA
		FR-S540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-NA (R)

	Jumper		Jumper
		N	P
N	P1	P	P1
			R	S	T	U	V	W

R

S

T

U

V

W

IM

IM

Power

Motor

Power

Motor

supply

supply

FR-S510W-0.1K, 0.2K, 0.4K-NA

FR-S510W-0.75K-NA

1

		N		P	N	P
R	S	U	V	W
						R	S	U	V	W

IM

Power			Motor					IM
supply				Power				Motor
				supply

CAUTION

•The power supply cables must be connected to R, S, T. If they are connected to U, V, W, the inverter will be damaged. (Phase sequence need not be matched.)

•Connect the motor to U, V, W.

Turning on the forward rotation switch (signal) at this time rotates the motor counterclockwise when viewed from the load shaft.

5

<When single-phase power input is provided for three-phase power input inverter (NA version only)>

Reduce the output current.

FR-S520- K-NA inverter	0.1	0.2	0.4	0.75	1.5	2.2	3.7
Rated output current (A)	0.4	0.8	1.5	2.5	4.0	5.0	7.0
Power supply capacity (kVA)	0.4	0.8	1.5	2.5	4.5	5.5	9.0
AC input current (A)	1.1	2.4	4.5	6.4	11.2	12.9	17.4

Set m9 (Pr. 637) "current detection filter".

Setting "801" in the manufacturer setting parameter C8 enables you to set the m9 parameter.

CAUTION

Parameters other than m9 can also be made to be displayed, but never alter these since they are manufacturer setting parameters.

	m9 Setting	Description
	0	Single-phase power input
	- - -	Three-phase power input
	(Factory setting)

CAUTION

Always return the C8 parameter to 0 (factory setting) after you have finished the setting of m9.

6

1.3 European Version

1.3.1 Terminal connection diagram

FR-S540-0.4K to 3.7K-EC(R)

Inverter

NFB MC

Motor

3-phase AC

L1

U

IM

power supply

L2

V

L3

W

Earth

Control input signals

(Ground)

(No voltage input allowed)

P1

Power factor improving

Contact input common

PC

DC reactor

(FR-BEL: Option)

Forward rotation start

STF

Jumper: Remove this

Reverse rotation start

STR

*4

jumper when FR-BEL

High

RH

*4

is connected.

Multi-speed selection Middle

RM

*4

*5

A

Low

RL

*4

*5

B

Alarm

*5

C

output

External transistor common

24VDC power supply

SD

*5RUN

Running

Operation status

Contact input common (sink)

output

SE

Open collector

Open

Take care not to short

output common

collector

terminals PC-SD.

outputs

SINK

(*2)

Frequency setting signals (Analog)

SOURCE

Frequency

3 2

10 (+5V)

setting

2 DC 0 to 5V

Selected

potentiometer

DC 0 to 10V

1

1/2W1k

5 (Common)

(*3)

Current input (-)

AM

(+) Analog signal

4 to 20mADC (+)

4 (4 to 20mADC)

output

5

(-)

(0 to 5VDC)

When using the current input as

1

the frequency setting signal, set

RS-485 Connector (*1)

"4" in any of Pr. 60 to Pr. 63 (input

terminal function selection), assign

Earth (Ground)

AU (current input selection) to any

of terminals RH, RM, RL and STR,

and turn on the AU signal.

Main circuit terminal Control circuit input terminal

Control circuit output terminal

REMARKS

*1 Only the type with RS-485 communication function.

*2 You can switch between the sink and source logic positions. Refer to page 25. *3 When the setting potentiometer is used frequently, use a 2W 1kΩ potentiometer. *4 The terminal functions change with input terminal function selection (Pr. 60 to

Pr. 63). (Refer to page 38, 88) (RES, RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, X14, X16, (STR) signal selection)

*5 The terminal functions change with output terminal function selection (Pr. 64, Pr. 65). (Refer to page 90) (RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, LF, ABC signal selection)

7

FR-S520S-0.2K to 1.5K-EC (R)

NFB MC

Motor

Power supply

L1

U

N

V

IM

W

Earth

(Ground)

REMARKS

•To ensure safety, connect the power input to the inverter via a magnetic contactor and earth leakage circuit breaker or no-fuse breaker, and use the magnetic contactor to switch power on-off.

•The output is three-phase 200V.

NOTE

•To prevent a malfunction due to noise, keep the signal cables more than 10cm (3.94inches) away from the power cables.

1.3.2 Layout and wiring of main circuit terminals

FR-S540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-EC (R)

Jumper

-	+
	P1

L1 L2 L3 U V W

IM

Power

Motor

supply

FR-S520S-0.2K, 0.4K, 0.75K-EC (R)

FR-S520S-1.5K-EC (R)

Jumper

Jumper

		-	+
-	P1	+	P1

L1

N

U

V

W

L1

N

U

V

W

IM

IM

Power

Motor

Power

Motor

supply

supply

CAUTION

•Connect the motor to U, V, W.

Turning on the forward rotation switch (signal) at this time rotates the motor counterclockwise when viewed from the load shaft.

•For power input wiring, connect L1 to R/L1 of the terminal block and N to S/L2 of the terminal block.

•Do not connect the power supply to U, V and W.

8

1.4 Description of I/O Terminal Specifications

1.4.1 Main circuit

	Symbol	Terminal Name	Description
	R, S, T *	AC power input	Connect to the commercial power supply.
	<L1, L2, L3>
	U, V, W	Inverter output	Connect a three-phase squirrel-cage motor.
	N<->	DC voltage	DC voltage common terminal. Not isolated from the
		common	power supply and inverter output.
		Power factor	Disconnect the jumper from terminals P<+>-P1 and
	P<+>, P1	improving DC	connect the optional power factor improving DC reactor
		reactor connection	(FR-BEL). (The single-phase 100V power input model
			cannot be connected.)

Earth (Ground) For grounding the inverter chassis. Must be earthed.

* R, S <L1, N> terminals for single-phase power input.

CAUTION

< >Terminal names in parentheses are those of the EC version.

1.4.2 Control circuit

Input signals

Symbol

		STF
input		STR
Contact		RH
		RM
		RL
SD
(*1)
PC
(*1)
10
setting		2
Frequency		4

Terminal Name	Description
Forward rotation	Turn on the STF signal	When the STF and STR
	to start forward rotation	signals are turned on
start
	and turn it off to stop.	simultaneously, the stop
Reverse rotation	Turn on the STR signal	command
	to start reverse rotation	is given.
start			Input terminal
	and turn it off to stop.
			function selection
	Turn on the RH, RM and RL signals
			(Pr. 60 to Pr. 63)
	in appropriate combinations to select
Multi-speed			changes the
	multiple speeds.		terminal functions.
selection	The priorities of the speed commands
			(*4)
	are in order of jog, multi-speed setting
	(RH, RM, RL, REX) and AU.
Contact input	Common terminal for contact inputs		(terminals STF, STR,
	RH, RM, RL) and indicator connection (terminal FM).
common (sink)
	Isolated from terminals 5 and SE.
					1
	When connecting the transistor output (open collector
External	output), such as a programmable controller (PLC),
transistor	connect the positive external power supply for transistor
common	output to this terminal to prevent a malfunction caused by
24VDC power	undesirable current.
supply	This terminal can be used as a 24V 0.1A DC power
Contact input	output across terminals PC-SD.
common (source)	When source logic is selected, this terminal serves as a
Frequency setting	contact input signal common.
	5VDC. Permissible load current 10mA.
power supply	By entering 0 to 5VDC (0 to 10VDC), the maximum
Frequency	output frequency is reached at 5V (10V) and I/O are
setting	proportional. Use Pr. 73 "0-5V/0-10V selection" to switch
(Voltage signal)	between 5V and 10V.
	Input resistance 10kΩ . Maximum permissible voltage 20V.
	Enter 4-20mADC. This signal is factory-adjusted to reach
Frequency	0Hz at 4mA and 60Hz at 20mA. Maximum permissible
	input current 30mA. Input resistance approximately 250Ω .
setting
	For current input, turn on the signal AU.
(Current signal)
	Set the AU signal in any of Pr. 60 to Pr. 63 (input
	terminal function selection).

9

		Symbol			Terminal Name			Description
	signals				Frequency	Common terminal for the frequency setting signals
		5			setting input	(terminals 2, 4) and indicator connection (terminal AM).
	Input				common	Isolated from terminals SD and SE. Do not earth.
						Change-over contact output indicating
		A				that the output has been stopped by the
						inverter's protective function activated.
		B			Alarm output	230V 0.3A AC, 30V 0.3A DC. Alarm:			Output
		C				discontinuity across B-C (continuity
									terminal
						across A-C), normal: continuity across
									function
						B-C (discontinuity across A-C). (*6)
									selection
		Open collector				Switched low when the inverter output			(Pr. 64, Pr. 65)
									changes the
						frequency is equal to or higher than the
									terminal
						starting frequency (factory set to 0.5Hz,
			RUN		Inverter running				functions. (*5)
	signals					variable). Switched high during stop or
						DC injection brake operation. (*2)
						Permissible load 24VDC 0.1A DC.
	Output	SE			Open collector	Common terminal	for inverter running		terminal RUN.
					output common	Isolated from terminals 5 and SD.
								Factory setting of output item:
					For meter	One selected from		Frequency
								Permissible load current 1mA
						output frequency
								1440 pulses/s at 60Hz
						and motor current is
						output.
		Indicator	AnalogPulse	AM FM <Japanese><NA, EC>
						The output signal is		Factory setting of output item:
					Analog signal	proportional to the
						magnitude of each		Frequency
					output	monitoring item.		Output signal 0 to 5VDC
								Permissible load current 1mA
	Communication					Using the parameter unit connection cable (FR-CB201 to
		−−			RS-485 connector	205), the parameter unit (FR-PU04) is connectable.
					(*3)	Communication operation can be performed through
						RS-485.

*1. Do not connect terminals SD and PC each other or to the earth.

For sink logic, 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 25 for the way to switch between them.)

*2. Low indicates that the open collector outputting transistor is on (conducts). High indicates that the transistor is off (does not conduct).

*3. Compatible with only the type having RS-485 communication function. (Refer to page 41.)

*4. RL, RM, RH, RT, AU, STOP, MRS, OH, REX, JOG, RES, X14, X16, (STR) signal selection (Refer to page 88.)

*5. RUN, SU, OL, FU, RY, Y12, Y13, FDN, FUP, RL, LF, ABC signal selection (Refer to page 90.)

*6. To be compatible with the European Directive (Low Voltage Directive), the operating capacity of relay outputs (A, B, C) should be 30V 0.3A DC.

10

1.5 How to Use the Main Circuit Terminals

1.5.1 Cables, wiring lengths, crimping terminals, etc.

The following selection example assumes the wiring length of 20m (65.62feet).

1)FR-S520-0.1K to 3.7K (-R) (-C) FR-S520-0.1K to 3.7K-NA

										PVC
	Applicable	Terminal	Tightening	Crimping			Cables			Insulated
	Inverter	Screw	Torque	Terminals						Cables
	Model	Size	N m			mm2		AWG		mm2
				R, S, T	U, V, W	R, S, T	U, V, W	R, S, T	U, V, W	R, S, T	U, V, W
	FR-S520-0.1K	M3.5	1.2	2-3.5	2-3.5	2	2	14	14	2.5	2.5
	to 0.75K
	FR-S520-	M4	1.5	2-4	2-4	2	2	14	14	2.5	2.5
	1.5K, 2.2K
	FR-S520-3.7K	M4	1.5	5.5-4	5.5-4	3.5	3.5	12	12	4	2.5

2)FR-S540-0.4K to 3.7K (-R) FR-S540-0.4K to 3.7K-NA (R) FR-S540-0.4K to 3.7K-EC (R)

										PVC
			Crimping				Cables			Insulated
Applicable	Terminal	Tightening	Terminals							Cables
Inverter	Screw	Torque			mm2			AWG		mm2
Model	Size	N m	R, S, T		R, S, T			R, S, T		R, S, T
			<L1, L2,	U, V, W	<L1, L2,	U, V, W		<L1, L2,	U, V, W	<L1, L2,	U, V, W
			L3>		L3>			L3>		L3>
FR-S540-0.4K	M4	1.5	2-4	2-4	2		2	14	14	2.5	2.5
to 3.7K

3)FR-S520S-0.1K to 1.5K (-R) FR-S520S-0.2K to 1.5K-EC (R)

PVC

Applicable

Terminal

Tightening

Crimping

Cables

Insulated

Terminals

Cables

Inverter

Screw

Torque

mm2

AWG

mm2

1

Model

Size

N m

R, S

U, V, W

R, S

U, V, W

R, S

U, V, W

R, S

U, V, W

<L1, N>

<L1, N>

<L1, N>

<L1, N>

FR-S520S-

M3.5

1.2

2-3.5

2-3.5

2

2

14

14

2.5

2.5

0.1K to 0.75K

FR-S520S-

M4

1.5

2-4

2-4

2

2

14

14

2.5

2.5

1.5K

4)FR-S510W-0.1K to 0.75K (-R) FR-S510W-0.1K to 0.75K-NA

										PVC
Applicable	Terminal	Tightening	Crimping				Cables			Insulated
			Terminals							Cables
Inverter	Screw	Torque
					mm2			AWG		mm2
Model	Size	N m
			R, S	U, V, W	R, S	U, V, W		R, S	U, V, W	R, S	U, V, W
										<L1, N>
FR-S510W-	M3.5	1.2	2-3.5	2-3.5	2		2	14	14	2.5	2.5
0.1K to 0.4K
FR-S510W-	M4	1.5	5.5-4	2-4	3.5		2	12	14	4	2.5
0.75K

11

Wiring length

100m (328.08feet) maximum. (50m (164.04feet) maximum for the FR-S540-0.4K.)

CAUTION

•When the wiring length of the 0.1K or 0.2K is 30m (98.43feet) or more, use the carrier frequency to 1kHz.

•Use the carrier frequency of 1kHz when the wiring length of the FR-S540-0.4K, 0.75K is 30m (98.43feet) or more.

•The wiring length should be 30m (98.43feet) maximum when automatic torque boost is selected in Pr. 98 "automatic torque boost selection (motor capacity)". (Refer to page 109)

1.5.2 Wiring instructions

1)Use insulation-sleeved crimping terminals for the power supply and motor cables.

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 off-cuts must not be left in the inverter.

Wire off-cuts can cause an alarm, failure or malfunction. Always keep the inverter clean.

When drilling a control box etc., take care not to let wire off-cuts 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 fast-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 harmonic components, which may interfere with the communication devices (such as AM radios) used near the inverter. In this case, install the optional FR-BIF radio noise filter (for use in 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 option) in the output side of the inverter.

This will cause the inverter to trip or the capacitor and surge suppressor to be damaged. If any of the above devices are connected, remove them. (When using the FR-BIF radio noise filter with a single-phase power supply, connect it to the input side of the inverter after isolating the T <L3> phase securely.)

8)Before starting rewiring or other work after performing operation once, check the voltage with a meter etc. more than 10 minutes after power-off. For some time after power-off, there is a dangerous voltage in the capacitor.

12

1.5.3 Peripheral devices

(1) Selection of peripheral devices

Check the capacity of the motor applicable to the inverter you purchased. Appropriate peripheral devices must be selected according to the capacity.

Refer to the following list and prepare appropriate peripheral devices:

1)FR-S520-0.1K to 3.7K (-R) (-C) FR-S520-0.1K to 3.7K-NA

	Motor		Rated current of	Magnetic	Power	Power	Cables (mm2)
					Factor	Factor	(*2)
		Inverter	Circuit Breaker	Contactor
	Output				Improving	Improving
	(kW	Model	(Refer to	(MC)	AC Reactor	DC Reactor
			page 15)	(Refer to			R, S, T	U, V, W
	(HP))		(*1)	page 17)	(Refer to	(Refer to
					page 18)	page 18)
	0.1	FR-S520-	30AF/5A	S-N10	FR-BAL-0.4K	FR-BEL-0.4K	2	2
	(1/8)	0.1K			(*3)	(*3)
	0.2	FR-S520-	30AF/5A	S-N10	FR-BAL-0.4K	FR-BEL-0.4K	2	2
	(1/4)	0.2K			(*3)	(*3)
	0.4	FR-S520-	30AF/5A	S-N10	FR-BAL-0.4K	FR-BEL-0.4K	2	2
	(1/2)	0.4K
	0.75	FR-S520-	30AF/10A	S-N10	FR-BAL-	FR-BEL-	2	2
	(1)	0.75K			0.75K	0.75K
	1.5	FR-S520-	30AF/15A	S-N10	FR-BAL-1.5K	FR-BEL-1.5K	2	2
	(2)	1.5K
	2.2	FR-S520-	30AF/20A	S-N11,	FR-BAL-2.2K	FR-BEL-2.2K	2	2
	(3)	2.2K		S-N12
	3.7	FR-S520-	30AF/30A	S-N20	FR-BAL-3.7K	FR-BAL-3.7K	3.5	3.5
	(5)	3.7K

2)FR-S540-0.4K to 3.7K (-R) FR-S540-0.4K to 3.7K-NA (R) FR-S540-0.4K to 3.7K-EC (R)

		Rated current of	Magnetic	Power	Power	Cables (mm2)		1
Motor				Factor	Factor	(*2)
		Circuit Breaker	Contactor
Output	Inverter			Improving	Improving
(kW	Model	(Refer to	(MC)	AC Reactor	DC Reactor	R, S, T	U, V, W
(HP))		page 15)	(Refer to	(Refer to	(Refer to	<L1, L2,
		(*1)	page 17)			L3>
				page 18)	page 18)
0.4	FR-S540-	30AF/5A	S-N10	FR-BAL-	FR-BEL-	2	2
(1/2)	0.4K			H0.4K	H0.4K
0.75	FR-S540-	30AF/5A	S-N10	FR-BAL-	FR-BEL-	2	2
(1)	0.75K			H0.75K	H0.75K
1.5	FR-S540-	30AF/10A	S-N10	FR-BAL-	FR-BEL-	2	2
(2)	1.5K			H1.5K	H1.5K
2.2	FR-S540-	30AF/15A	S-N20	FR-BAL-	FR-BEL-	2	2
(3)	2.2K			H2.2K	H2.2K
3.7	FR-S540-	30AF/20A	S-N20	FR-BAL-	FR-BAL-	2	2
(5)	3.7K			H3.7K	H3.7K

13

3)FR-S520S-0.1K to 1.5K (-R) FR-S520S-0.2K to 1.5K-EC (R)

					Power	Power	Cables (mm2)
	Motor		Rated current of	Magnetic	Factor	Factor	(*2)
			Circuit Breaker	Contactor	Improving	Improving
	Output	Inverter
			(Refer to	(MC)	AC Reactor	DC Reactor
	(kW	Model					R, S
			page 15)	(Refer to	(Refer to	(Refer to		U, V, W
	(HP))						<L1, N>
			(*1)	page 17)	page 18)	page 18)
					(*3)	(*3)
	0.1	FR-S520S-	30AF/5A	S-N10	FR-BAL-0.4K	FR-BEL-0.4K	2	2
	(1/8)	0.1K
	0.2	FR-S520S-	30AF/10A	S-N10	FR-BAL-0.4K	FR-BEL-0.4K	2	2
	(1/4)	0.2K
	0.4	FR-S520S-	30AF/10A	S-N20	FR-BAL-	FR-BEL-	2	2
	(1/2)	0.4K			0.75K	0.75K
	0.75	FR-S520S-	30AF/15A	S-N20	FR-BAL-1.5K	FR-BEL-1.5K	2	2
	(1)	0.75K
	1.5	FR-S520S-	30AF/20A	S-N21	FR-BAL-2.2K	FR-BEL-2.2K	2	2
	(2)	1.5K

4)FR-S510W-0.1K to 0.75K (-R) FR-S510W-0.1K to 0.75K-NA

					Power	Power	Cables (mm2)
	Motor		Rated current of	Magnetic	Factor	Factor	(*2)
			Circuit Breaker	Contactor	Improving	Improving
	Output	Inverter
			(Refer to	(MC)	AC Reactor DC Reactor
	(kW	Model					R, S
			page 15)	(Refer to	(Refer to	(Refer to		U, V, W
	(HP))						<L1, N>
			(*1)	page 17)	page 18)	page 18)
					(*3)	(*4)
	0.1	FR-S510W-	30AF/10A	S-N10	FR-BAL-	−−	2	2
	(1/8)	0.1K			0.75K
	0.2	FR-S510W-	30AF/15A	S-N10	FR-BAL-1.5K	−−	2	2
	(1/4)	0.2K
	0.4	FR-S510W-	30AF/20A	S-N20	FR-BAL-2.2K	−−	2	2
	(1/2)	0.4K
	0.75	FR-S510W-	30AF/30A	S-N20	FR-BAL-3.7K	−−	3.5	2
	(1)	0.75K

*1 For installations in the United States or Canada, the circuit breaker must be inverse time or instantaneous trip type.

*2 The size of the cables assume that the wiring length is 20m (65.62feet). *3 The power factor may be slightly less.

*4 The single-phase 100V power input model does not allow the power factor improving DC reactor to be fitted.

14

1.5.4 Leakage current and installation of earth 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 counter measures.

(1) To-ground leakage currents

Leakage currents may flow not only into the inverter's own line but also into the other line through the ground cable, etc.

These leakage currents may operate earth leakage circuit breakers and earth leakage relays unnecessarily.

Counter measures

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 (e.g. Mitsubishi's Progressive Super Series) in the inverter's own line and other line, operation can be performed with the carrier frequency kept high (with low noise).

(2) Line-to-line leakage currents

	Harmonics of leakage	NFB	Thermal relay	Motor
	currents flowing in static	Power	Inverter	IM
	capacities between the
		supply

	inverter output cables	Line static
	may operate the external
		capacitances
	thermal relay
		Line-to-Line Leakage Current Path
	unnecessarily.

Counter measures

Use the electronic overcurrent protection 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 1 recommended to use a temperature sensor to directly detect motor temperature.

Installation and selection of no-fuse breaker

On the power receiving side, install a no-fuse breaker (NFB) to protect the primary wiring of the inverter. Which NFB to choose depends on the power supply side power factor (which changes with the power supply voltage, output frequency and load) of the inverter. Especially as the completely electromagnetic type NFB changes in operational characteristic with harmonic currents, you need to choose the one of a little larger capacity. (Check the data of the corresponding breaker.) For the earth leakage circuit breaker, use our product designed for harmonic and surge suppression (Progressive Super Series). (Refer to page 13 for the recommended models.)

CAUTION

Choose the NFB type according to the power supply capacity.

15

(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:

Progressive Super Series	Example of leakage	Leakage current
(Type SP, CF, SF, CP)	current per 1km in cable	example of 3-phase
Rated sensitivity current:	path during commercial	induction motor
I∆ n ≥ 10 × (lg1+Ign+lg2+lgm)	power supply operation	during commercial
Conventional NV series (Type CA,	when the CV cable is	power supply
CS, SS produced prior to '91)	routed in metal conduit	operation
Rated sensitivity current:	(200V 60Hz)	(200V 60Hz)

I∆ n ≥	10 × {lg1+lgn+3 × (lg2+lgm)}																	(mA)			120																								(mA)	2.0
lg1, lg2 : Leakage currents of cable																					100																									1.0
	path during commercial																				80																									0.7
																		current																											current
	power supply operation																				60																									0.5
																																														0.3
lgn*	: Leakage current of noise																				40
																																														0.2
	filter on inverter input side																	Leakage			20																								Leakage	0.1
lgm	: Leakage current of motor																				0
																						2 3.5									8 142238 80150															1.5 3.7 7.5 15223755
	during commercial power																					5.5									30 60100															2.2 5.5 1118.53045
	supply operation																																								2
																					Cable size (mm )																									Motor capacity (kW)
<Example>
					2mm2 ×5m 2mm2 ×70m
					(16.40feet)															(229.66feet)
			NV						Noise
											filter																											3
															Inver-
																																	IM						200V
															ter																								1.5kW
																																							(2HP)

					Ig1 Ign	Ig2	Igm
		CAUTION
•
	The earth leakage circuit breaker should be installed to the primary (power
•	supply) side of the inverter.
	In the			connection neutral point grounded system, the sensitivity current

becomes worse for ground faults in the inverter secondary side. Hence, the protective grounding of the load equipment should be 10Ω or less.

•When the breaker is installed in 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.

*Note the leakage current value of the noise filter installed on the inverter input side.

	Progressive Super Series			Conventional NV
	(Type SP, CF, SF,CP)			(Type CA, CS, SS)
Leakage current (Ig1) (mA)	20 ×	5m (16.40feet)			= 0.10
		1000m (3280.80feet)
Leakage current (Ign) (mA)		0 (without noise filter)
Leakage current (Ig2) (mA)	20 ×	70m (229.66feet)			= 1.40
		1000m (3280.80feet)
Motor leakage		0.14
current (Igm) (mA)
Total leakage current (mA)	1.66				4.78
Rated sensitivity current	30				100
(mA) ( ≥ Ig × 10)

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1.5.5 Power-off and magnetic contactor (MC)

CAUTION

Do not use the inverter power supply side magnetic contactor to start or stop the inverter.

As shown on the right, always use the start signal (ON or OFF across terminals STF or STR-SD) to make a start or stop. (Refer to page 28)

NFB

Power supply

F

OFF

MC

OFF

	MC
	R<L1>	U
	S<N>	V	To
			motor
	T	W

			B
	ON		OFF
		MC
	MC		C

ON	Inverter

RA

RA

RA

STF (STR)

SD

Inverter Start/Stop Circuit Example

(1) Inverter's primary side magnetic contactor (MC)

On the inverter's primary side, it is recommended to provide an MC for the following purposes (Refer to page 13 for selection.):

1)To release the inverter from the power supply when the inverter's protective function is activated or when the drive is not functioning (e.g. emergency stop

operation).

2) To prevent an accident caused by an automatic restart made at power restoration 1 after an inverter stop due to a power failure.

3)To rest the inverter for a long time.

The control power supply for inverter is always running and consumes a little power. When stopping the inverter for a long time, switching inverter power off saves power slightly.

4)To separate the inverter from the power supply to ensure safety of maintenance/inspection work.

As the inverter's primary MC is used for the above purposes, it is equivalent to the standard duty and select the one of class JEM1038-AC3 for the inverter input side current.

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1.5.6 Regarding the installation of the power factor improving reactor

When the inverter is installed near a large-capacity power transformer (500kVA or more at 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 power factor improving reactor (FR-BEL or FR-BAL).

	NFB				FR-BAL				Inverter
					R			X
Power									R<L1>U
					S			Y
									S<N> V
supply
					T			Z	T	W

P<+>P1

FR-BEL(*)

Power supply equipment

		1500	Power factor
		1000	improving reactor
	(kVA)		installation range
		500

	capacity
		0		10

Wiring length (m)

REMARKS

*When connecting the FR-BEL, remove the jumper across terminals P<+>-P1. The wiring length between FR-BEL and inverter should be 5m (16.40feet) maximum and as short as possible.

Use the cables which are equal in size to those of the main circuit. (Refer to page 11)

1.5.7 Regarding noise 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 be insusceptible to noise, it handles low-level signals, so it requires the following general counter measures to be taken.

General counter measures

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.

Ground the inverter, motor, etc. at one point.

Capacitances exist between the inverter's I/O wiring, other cables, earth and motor, through which leakage currents flow to cause the earth leakage circuit breaker, earth 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 leakage circuit breaker designed for suppression of harmonics and surges, and use the electronic overcurrent protection built in the inverter.

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Noise reduction examples

FR-BLF

Control

Reduce carrier

FR-BLF

Install filter FR-BSF01

box

frequency.

Install filter

FR-BSF01

on inverter's input side.

on inverter's output side.

Inverter

FR-

FR-

Inverter

IM Motor

BLF

BLF

power supply

Install filter FR-BIF

FR-

Use 4-core cable for motor

on inverter's input side.

Separate inverter and power

BIF

power cable and use one

cable as earth cable.

line more than 30cm (3.94inches)

(at least 10cm (11.81inches))

Use twisted pair shielded cable.

from sensor circuit.

Power

Sensor

Control

supply

power supply Do not earth control

for sensor

box directly.

Do not earth shield but connect

Do not earth

it to signal common cable.

control cable.

1.5.8 Grounding precautions

Leakage currents flow in the inverter. To prevent an electric shock, the inverter and motor must be grounded.

Use the dedicated ground terminal to ground the inverter. (Do not use the screw in the casing, chassis, etc.)

Use a tinned* crimping terminal to connect the earth cable. When tightening the screw, be careful not to break the threads.

*Plating should not include zinc.

Use the thickest possible ground cable. Use the cable whose size is equal to or

greater than that indicated in the following table, and minimize the cable length. 1 The grounding point should be as near as possible to the inverter.

			(Unit: mm2)
	Motor Capacity	Ground Cable Size
		200V, 100V class	400V class
	2.2kW (3HP) or less	2 (2.5)	2 (2.5)
	3.7kW (5HP)	3.5 (4)	2 (4)

For use as a product compliant with the Low Voltage Directive, use PVC cable whose size is indicated within parentheses.

Ground the motor on the inverter side using one cable of the 4-core cable.

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1.5.9 Regarding power harmonics

The inverter may generate power harmonics from its converter circuit to affect the power generator, power capacitor etc. Power harmonics are different from noise and leakage currents in source, frequency band and transmission path. Take the following counter measure suppression techniques.

The following table indicates differences between harmonics and noise:

	Item	Harmonics	Noise
	Frequency	Normally 40th to 50th degrees or	High frequency (several 10kHz
		less (up to 3kHz or less)	to MHz order)
	Environment	To-electric channel, power	To-space, distance, wiring path
		impedance
	Quantitative	Theoretical calculation possible	Random occurrence, quantitative
	understanding		grasping difficult
	Generated amount	Nearly proportional to load	Change with current	variation
			ratio (larger as switching speed
		capacity
			increases)
	Affected equipment	Specified in standard per	Different depending on	maker's
	immunity	equipment	equipment specifications
	Suppression example	Provide reactor.	Increase distance.

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 power factor improving reactor and the magnitudes of output frequency and output current on the load side.

Power factor

NFB

improving DC reactor

Inverter

Motor

IM

Power factor

Do not provide power factor

improving AC reactor

improving capacitor.

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 harmonic 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 power factor improving reactor in the inverter's primary side or DC circuit. For full information, refer to page 18.

1.5.10 Japanese power 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 harmonics.

1)[Harmonic suppression guideline for household appliances and general-purpose products]

The "harmonic suppression guideline for household appliances and general-purpose products" issued by ex-Ministry of International Trade and Industry (present Ministry of Economy, Trade and Industry) in September, 1994 applies to the FR-S500 series other than the three-phase 400V class. By installing the FR-BEL or FR-BAL power factor improving reactor, this product complies with the "harmonic suppression techniques for transistorized inverters (input current 20A or less)" established by the Japan Electrical Manufacturers' Association.

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2)"Harmonic suppression guideline for specific consumers"

This guideline sets forth the maximum values of harmonic currents outgoing from a high-voltage or specially 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	Over
									23rd
	6.6kV	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

(1)Application of the harmonic suppression guideline for specific consumers

New installation/addition/ renewal of equipment

Calculation of equivalent capacity sum

Not more than
reference capacity			Sum of equivalent
			capacities
	Over reference
	capacity								1
		Calculation of outgoing
		harmonic current
			Is outgoing harmonic			Over maximum value
			current equal to or lower
			than maximum value?

				Harmonic suppression
		Not more than		technique is required.
		maximum value
	Harmonic suppression
	technique is not required.

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