Mitsubishi Electronics FR-A500 User Manual

HIGH POWER FACTOR CONVERTER

FR-HC-7.5K to 55K FR-HC-H7.5K to H55K

INSTRUCTION MANUAL

Thank you for choosing the Mitsubishi High Power Factor Converter. This instruction manual gives handling information and precautions for use of this equipment. Incorrect handling might cause an unexpected fault. Before using the invert er, please read this manual care fully to us e the equipment to its optimum. Please forward this manual to the end user.

Safety Instructions

Do not attempt to install, operat e, maintain or i nspec t the unit until you have read through this ins tr ucti on manual and appended docu ments carefully and can use the equipme nt correctly. Do not use the unit 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”.

Assumes that incorrect handling may cause hazardous conditions,

WARNING CAUTION

resulting in death or severe injury.

Assumes that in correc t handl ing may cause h azardou s cond itions, r esulti ng in medium or slight injury, or may cause physical damage only.

Note that the level may lead to a serious consequen ce accordi ng to con ditions. Plea se follow the instructions of both levels because they are important to personnel safety.

CAUTION

- A-1 -

SAFETY INSTRUCTIO NS

1. Electric Shock Prevention

WARNING

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

• Do not run the equipment with the front co ver remo ved. Oth erwis e, you may acces s the expo sed high voltage terminals and charging part and get an electric shock.

• If power is off, do not remove the front cover except fo r wiring or periodic inspection . You may access the charged circuits of the inverter and high power factor converter and get an electric shock.

• Before starting wiring or ins pe ction, ch ec k fo r res i dual v oltages wi th a m ete r etc. more than 10 minutes after power-off.

• This converter must be ear the d (gr ou nde d). Earthing (grounding) mu st be c on for m to the requi r eme nts of national and local safety regul ations and electrical codes. (NEC section 250, IEC 536 class 1 and other applicable standa rd s)

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

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

• Operate the switches with dry hands to prevent an electric shock.

• Do not subject the c ab les to s cratc he s, ex ce ss iv e str ess , heavy loads or pi nchi ng. O th er wis e, you may get an electric shock.

2. Fire Prevention

CAUTION

• Mount the high power fa ctor conver ter on a non- combustible sur face. Installing the equipment directly on or near a combustible surface could lead to a fire.

• Power off the high power factor converter if it has failed. A continuous flow of a large current can cause a fire.

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

• When a brake resistor is used, switch po wer off if an alarm signal app ears on the PU. Otherwi se, the brake resistor may excessively overheat due to damage of the brake transistor, etc., causing a fire.

3. Injury Prevention

CAUTION

• Apply only the volta ge specified in the inst ruction manual to each te rminal to prevent bu rst, damage, etc.

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

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

• While power is on or for some time after power-off, do not touch the inverter, high power factor converter, reactors 1 and 2, or the external box as they are hot and you may get burnt.

- A-2 -

4. Additional instructions

To prevent injury, damage or product failure, please note the following points.

(1)Transportation and mounting

CAUTION

• Please use common sense when carrying the product. Not doing so can cause injury.

• Do not stack the equipment higher than the number recommended.

• Install the product in a load-bearing place in accordance with the instruction manual.

• Do not operate if the high power factor converter is damaged or has parts missing.

• Do not lift the equipment with the front cover attached; it may fall off.

• Do not stand or rest heavy objects on the product.

• Check the equipment mounting orientation is correct.

• Prevent any dust, wire fragments or other foreign bodies from dropping into the high power factor converter.

• Do not drop the high power factor converter, or subject it to impact.

• Use the equipment under the following environmental conditions:

Ambient

temperature

Ambient humidity

Storage

temperature

Environment

Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)

Altitude, vibration

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

(-10°C to +40°C when the d ust-protec tion structure attachment is used)

Maximum 1000m above sea level for standard operation.

After that derate by 3% for every extra 500m up to 2500m (91%).

-10°C to +50°C (non-freezing)

90%RH or less (non-condensing )

-20°C to +65°C*

5.9m/s

or less

(2)Trail run

CAUTION

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

• Before starting operation, e nsure that each peripheral device is wired pr operly. Incorrect connection may lead to unexpected operation.

(3)Operation

CAUTION

• The load used must be a three-phase induction motor. If any other electrical equipment is connected to the inverter output, the equipment may be damaged.

• Do not modify the equipment.

- A-3 -

(4)Emergency stop

CAUTION

• Provide a safety backup such as an emer gecy brake which will prevent the machine and equipment from hazardous conditions if the high power factor converter fails.

• When any protective function is activated, take the corresponding corrective action, then reset the inverter, and resume operation.

(5)Maintenance, inspection and parts replacement

CAUTION

• Do not carry out a megger (insulation resistance) test on the control circuit of the high power factor converter.

(6)Disposal

CAUTION

• Treat the equipment as industrial waste.

(7)General instructions

Many of the diagrams and drawing in this instruction manual show the equipment without a cover, or partiall y open. Never run the inverter like thi s. Always replace th e cover and ensure adequate coo ling, etc. before using the product.

- A-4 -

1. OVERVIEW

1.1 PRECAUTIONS FOR OPERATION ................................ ...... ....................................... ...... ..... ...... ..........................1

1.1.1 Japanese harmonic suppression guideline .......................................................................................................1

1.1.2 Pre-operation procedure ....................................................................................................................................5

1.1.3 Handling precautions .........................................................................................................................................6

1.2 STRUCTURE ...........................................................................................................................................................7

1.2.1 Structure ............................................................................................................................................................7

1.2.2 Removal and reinstallation of the front cover ....................................................................................................8

1.2.3 Removal and reinstallation of the accessory cover .........................................................................................11

1.2.4 Removal and reinstallation of the parameter unit (FR-PU02) ..........................................................................12

1.3 INSTALLATION AND WIRING ................................... ..... ...... ....................................... ...... ..... ..............................13

1.3.1 Precautions for installation ................................... ....................................... ...... ..... .........................................13

1.3.2 Wiring instructions ...........................................................................................................................................16

1.3.3 Wiring of the main circuit ..................... ....................................... ...... ...............................................................17

1.3.4 Wiring of the control circuit .................. ....................................... ...... ...............................................................26

2. PARAMETERS

2.1 PARAMETER UNIT ...............................................................................................................................................29

2.1.1 Structure of the parameter unit ........................................................................................................................29

2.1.2 Setting and changing the parameter values ....................................................................................................30

2.2 PARAMETER FUNCTION DETAILS .....................................................................................................................31

2.2.1 Parameter list ..................................................................................................................................................31

2.2.2 Setting of parameters to improve the corresponding operational functions ....................................................32

Pr.1 “power supply frequency 1”, Pr.2 “power supply frequency 2” .......................................................................32

Pr.22 “overload signal detection level” ..................................................................................................................32

Pr.40 “output terminal assignment” .......................................................................................................................32

Pr. 51 “input power monitoring refer ence”, Pr. 53 “input voltage monitoring reference”, Pr. 55 “bus voltage monitori ng

reference”, Pr. 56 “current monitoring reference” ...................................................................................................33

Pr. 52 “PU main display data selection”, Pr. 54 “FM terminal function selection” ...................................................33

Pr.57 “restart selection” .........................................................................................................................................35

Pr. 65 “retry selection”, Pr. 67 “number of retries at al arm occurrence”, Pr. 68 “retry waiting t ime”, Pr. 69 “retry coun t

display erasure” ........................................................... ..... ........................................ ..... .........................................36

Pr.77 “parameter write disable selection” ..............................................................................................................37

Pr.145 “parameter unit language switching” ..........................................................................................................37

Pr.900 “FM terminal calibration” ............................................................................................................................38

2.3 HELP FUNCTIONS ................................................................................................................................................40

2.3.1 Definitions of the help function displays ..........................................................................................................40

2.4 CONVERTER RESET ............................................................ ...... ..... ...... ..... ...... ....................................................43

3. PROTECTIVE FUNCTIONS

3.1 ERRORS ................................................................................................................................................................44

3.1.1 Error (alarm) definitions and remedies .............................................................. ..... ...... ...................................44

3.1.2 Faults and check points ...................................................................................................................................45

- I -

3.2 MAINTENANCE AND INSPECTION .....................................................................................................................46

3.2.1 Precautions for maintenance and inspection ...................................................................................................46

3.2.2 Check items .....................................................................................................................................................46

3.2.3 Replacement of parts ...................................................................................................................................... 49

3.2.4 Measurement of main circuit voltages, currents and powers ..........................................................................50

4. PRECAUTIONS FOR SELECTION

4.1 PRECAUTIONS FOR SELECTING PERIPHERAL DEVICES ..............................................................................52

4.1.1 Measures against noises .................................................................................................................................52

4.1.2 Peripheral device list .......................................................................................................................................55

4.1.3 Selecting the rated sensitivity current for the earth leakage circuit breaker ....................................................55

5. SPECIFICATIONS

5.1 SPECIFICATIONS .................................................................................................................................................56

5.1.1 Standard specifications ...................................................................................................................................56

5.1.2 Block diagram ..................................................................................................................................................57

5.1.3 Terminals .........................................................................................................................................................58

5.1.4 Terminal block arrangement ............................................................................................................................60

5.1.5 Outline drawings (400V class models have H in their type codes) ..................................................................61

5.1.6 Panel cutting dimension diagrams (For use of the heat sink outside mounting attachment) ...........................66

5.1.7 Parameter unit (FR-PU02-1/FR-PU02E-1/FR-PU02ER-1) dimension diagram ..............................................67

5.2 OPTIONS ...............................................................................................................................................................68

5.2.1 Option list .........................................................................................................................................................68

5.2.2 External dedicated options ..............................................................................................................................69

APPENDIX

APPENDIX 1 INSTRUCTIONS FOR COMPLIANCE WITH THE EUROPEAN STANDARDS .............................73

APPENDIX 2 Instructions for UL and cUL ..........................................................................................................74

- II -

1. OVERVIEW

2. PARAMETERS

3. PROTECTIVE FUNCTIONS

4. PRECAUTIONS FOR SELECTION

5. SPECIFICATIONS

1. OVERVIEW

This chapter provides an “overview” of this product. Always read the precautions, etc. before starting use.

1.1 PRECAUTIONS FOR OPERATION........................................................... 1

1.2 STRUCTURE ............................................................................................. 7

1.3 INSTALLATION AND WIRING................................................................... 13

1.1 PRECAUTIONS FOR OPERATION

Incorrect handling might cause the equipment to operate improperly, its life to be reduced considerably, and in the worst case, the high power factor converter and inverter to be damaged. Please handle the unit properly in accordance with the information on each section as well as the precautions and instructions of this manual.

FR-HC Function

The FR-HC high power factor converter provides three functions

1) Inverter generated mains harmonics reduction See the Power harmonic guideline section below.

2) Near unity power factor at 100% load Gives better efficiency and lower stress on power line components.

3) Regeneration of load to the mains power supply The FR-HC can con tinuously re generate conver ter rated current t o the power su pply, for example from a ‘back-driving’ load such as a d own escalator. This gives very efficient full 4-quadrant control of the AC motor from the inverter without the need for brake resistors or braking units etc.

1.1.1 Japanese harmonic suppression guideline

Harmonic c urrents flow from th e inverter to a power receiv ing point via a p ower 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” 200V class inver ters of 3.7kW and less are covered by this guideline. Install a power factor improving reactor to comply with this guideline.

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 con sumer who will install, add or renew harm onic generating equipment. If any of the maximum values is exceeded, this g uideline requ ires that c onsumer to ta ke cer tain suppre ssion measures.

Table 1 Maximum Values of Outgoing Harmonic Currents per 1kW Contract Power

Received

Power

Voltage

6.6kV 3.5 2.5 1.6 1.3 1.0 0.9 0.76 0.70 22kV 1.8 1.3 0 .82 0.69 0.53 0.47 0.39 0.36 33kV 1.2 0.86 0.55 0.46 0.35 0. 32 0.26 0.2 4

5th 7th 11th 13th 17th 19th 23rd

over 23rd

- 1 -

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

New installation/addition/renewal of

harmonic generating equipment

Calculation of equivalent capacity sum

Not more than reference capacity

Over reference capacity

Sum of equivalent capacities

Calculation of outgoing harmon ic

current higher than maximum

Harmonic suppression techn iq ue is

current

Is outgoing harmonic

value?

Not more than maximum value

not required.

Over maximum value

Harmonic suppression technique is required.

Table 2 Conversion Factors for FR-A500 Series

Classification Circuit Type Conversion Factor

Without reactor K31=3.4

Three-phase bridge

(Capacitor smoothed)

With reactor (on AC side) K32=1.8 With reactor (on DC side) K33=1.8

Without reactor (on AC/DC side) K34=1.4

5 Self-excited three-phase bridge When high power factor converter is used K5=0

Table 3 Equivalent Capacity Limits

Received Power

Voltage

6.6kV 50kVA

22/23kV 300kVA

66kV or more 2000kVA

Reference

Capacity

Table 4 Harmonic Content (Values at the fundamental current of 100%)

Reactor 5th 7th 11th 13th 17th 19th 23rd 25th

Not used 65 41 8.5 7.7 4.3 3.1 2.6 1.8 Used (AC side) 38 14.5 7.4 3.4 3.2 1.9 1.7 1.3 Used (DC side) 3 0 13 8.4 5.0 4.7 3.2 3.0 2.2 Used (AC, DC sides) 28 9.1 7.2 4.1 3.2 2.4 1.6 1.4

- 2 -

1) Calculation of equivalent capacity P0 of harmonic generating equipment

The “equivalent capacity” is the capacity of a 6-pulse converter converted from the capacity of a consumer’s harmonic generat ing equip ment and i s calcula ted with the following equation. If the s um of equivalent capacities is hig her than the limit in Table 3, har monics must be calcul ated in the following procedure:

P0 = (Ki×Pi) [kVA]

Ki: Conversion factor (refer to Table 2) Pi: Rated capacity of harmonic generating equipment* [kVA] i: Number indicating the conversion circuit type

* Rated capacity: Determined by the

capacity of the applied motor and found in Table 5. It should be noted that the rated capacity used here is used to calculate generated harmonic amount and is different from the power supply capacity require d for actual inverter drive.

2) Calculati on of outgoi ng harmonic current Outgoing harm oni c

current

(value converted from received power voltage)

fundamental wave current

operation

ratio

harmonic

content

• Operation ratio: Operation ratio = actual load factor × operation tim ratio during 30 minutes

• Harmonic content: Found in Table 4.

Table 5 Rated Capacities and Outgoing Harmonic Currents for Inverter Drive

Applied

Motor

(kW)

0.4

0.75

1.5

2.2

3.7

5.5 19.1 9.55 579 6.77 376.1 237.4 49.22 44.58 24.90 17.95 15.05 10.42

7.5 25.6 12.8 776 9.07 504.4 318.2 65.96 59.75 33.37 24.06 20.18 13.97 11 36.9 18.5 1121 13.1 728.7 459.6 95.29 86.32 48.20 34.75 29.15 20.18 15 49.8 24.9 1509 17.6 980.9 618.7 128.3 116.2 64.89 46.78 39.24 27.16

18.5 61.4 30.7 1860 21.8 1209 762.6 158.1 143.2 79.98 57.66 48.36 33.48 22 73.1 36.6 2220 25.9 1443 910.2 188.7 170.9 95.46 68.82 57.72 39.96 30 98.0 49.0 2970 34.7 1931 1218 252.5 228.7 127.7 92.07 77.22 53.46 37 121 60.4 3660 42.8 2379 1501 311.1 281.8 157.4 1 13.5 95.16 65.88 45 147 73.5 4450 52.1 2893 1825 378.3 342.7 191.4 1 38.0 115.7 80.10 55 180 89.9 5450 63.7 3543 2235 463.3 419.7 234.4 1 69.0 141.7 98.10

Rated

Current

[A]

200V 400V 5th 7th 11th 13th 17th 19th 23rd 25th

1.61

(Note)

0.81 49 0.57 31.85 2 0.09 4.165 3.773 2.107 1.519 1.274 0.882

2.74

1.37 83 0.97 53.95 3 4.03 7.055 6.391 3.569 2.573 2.158 1.494

5.50

2.75 167 1.95 108.6 68.47 14.20 12.86 7.181 5.177 4.342 3.006

7.93

3.96 240 2.81 156.0 98.40 20.40 18.48 10.32 7.440 6.240 4.320

13.0

6.50 394 4.61 257.1 161.5 33.49 30.34 16.94 12.21 10.24 7.092

Fundamental

Wave Current

Converted fr om

6.6kV (mA)

Rated

Capacity

(kVA)

Fundamental Wave Current Converted from 6.6kV(mA)

(No reactor, 100% operation ratio)

Note:When a motor of 3.7kW or less capaci ty is driven by a transistorized inverter of more than 3.7kW.

For example, when a 3.7kW or less motor is driven by a 5.5kW transistorized inverter, the transistorized inverter is not the target of the household appliances/general-purpose products guideline, but because they must be included in the calculation of the har monic current of the guideline, the fundamental wave input currents are indicated.

3) Harmonic suppression technique requirement contract

If the outgoing harmoni c current is higher than the maximum value per 1kW co ntract power × power, a harmonic suppression technique is required.

- 3 -

4) Harmonic suppression techniques

No. Item Description

Reactor installation

(ACL, DCL) High power factor

converter (FR-HC) Installation of power

factor improving capacitor Transformer multi-phase

operation

5AC filter

6 Active filter

Install a reactor (ACL) in the AC side of the inverter or a reactor (DCL) in its DC s ide or both to suppress harmonic currents.

Designed to switch the converter circuit on-off to convert an input current waveform into a sine wave, the high power factor converter (FR-HC) suppresses harmonic current considerably. The FR-HC is used with the standard accessories.

When used with a series reactor, the power factor improving capacitor has an effect of absorbing harmonic currents.

Use two transformers with a phase angle difference of 30° as in - , - combination to provide an effect corresponding to 12 pulses, reducing low-degree harmonic currents.

A capacitor and a reactor are used together to reduce impedance at specific frequencies, producing a great effect of absorbing harmonic currents.

This filter detects the current of a circuit generating a harmonic current and generates a harmonic current equivalent to a difference between that current and a fundamental wave current to suppress a harmonic current at a detection point, providing a great effect of absorbing harmonic currents.

∆∆∆

(2) Features of the FR-HC (high power factor converter)

The converter circuit of an inverter generates power harmonics, which may affect a generator, power capacitor, etc. Power harmonics are different from noises and leakage currents in their sources, frequency bands and transmission routes. Th erefore, securely connect the high power factor converter (FR-HC) with the FR series inverter, and refer to the inverter instruction manual on how to set the parameters. The conversion factor of the high power factor converter is K5=0 for a self-excited, threephase bridge circuit:

Making the above settings suppresses power harmonics to conform to the harmonic suppression guidelines published by the Ministry of International Trade and Industry.

• Power harmonic su ppr ess ion effect (Example) FR-HC-7.5K (Environment) Load: 100%

Power factor: 1

[FR-HC not connected]

Phase voltage (100V/div)

Phase current

(50A/div)

Phase voltage (100V/div)

Phase current

[FR-HC connecte d]

(50A/div)

- 4 -

1.1.2 Pre-operation procedure

1. Unpacking and product check

Unpack the product and ch eck the ca pa ci ty plat e on t he fron t cover and the ratin g pl at e on the equ ip me nt side face to ensure that the type and output rating agree with your order and the product is intact. When using reactors 1, 2 and the external box, especially when they are used with the Mitsubishi transistorized inverter be sure to us e them as a set and make sure they are securely con nected. This high power factor converter suppresses har monics according to the harmonic suppressio n guidelines published by Ministry of Economy Trade and Industry (formerly Ministry of International, Trade and Industry). Pay attention to the applicable capacity, etc.

Rating plate

Capacity plate

High power factor converter type

Serial number

Rated input current Serial number

Converter type Applicable inverter

capacity Applicable power

supply

• Definition of the high power factor converter type

FR-HC- K

Symbol

None

Voltage class

200V class 400V class

7.5 to 55

Applicable inverter capacity

Capacity in "kW"

• Confirmation of the peripheral device types

The following three peripheral devices, FR-HCL01, FR-HCL02 and FR-HCB, must be installed. Confirm their types:

High Power Factor Converter

FR-HC-7.5K FR-HCL01-7.5K FR-HCL02-7.5K FR-HCB-7.5K FR-HC-15K FR-HCL01-15K FR-HCL02-15K FR-HCB-15K FR-HC-30K FR-HCL01-30K FR-HCL02-30K FR-HCB-30K FR-HC-55K FR-HCL01-55K FR-HCL02-55K FR-HCB-55K

Reactor 1 Reactor 2 External Box

Note: 400V class devices have capacity numbers preceded by H in their type codes.

• Accessory . . . . . . Instruction manual

If you have found any discrepancy, damage, etc., please contact your sales representative.

2. Installation

To operate the product with high performance for a long time, install it in a p roper place, in a correct direction, and with proper clearances. (See page 13.)

3. Wiring

Securely connec t the p ower supply, reactors 1, 2, external box, high power factor converter a nd inver ter to the terminal blocks. If they are connected im properly, the periph eral devices and the high power factor converter itself may be damaged. (See page 16.) After making su re that the wiring is secured, refer to the i nverter instruc tion manual on how to set the parameters.

Note: If the inverter is provided with a jum per connector for sink and source logic change, fit the jumpe r

connector to the sink logic (factor y settin g) when c onnecting a high power factor converter (FR-HC). If the jumper connector is fitted to the source logic, the converter cannot be connected.

- 5 -

1.1.3 Handling precautions

The following system is required to operate the inverter. Install the high power factor converter in a proper position. For the selection and specifications of each peripheral device, refer to “Precautions for Selecting Peripheral Devices” on page 52:

Name Description Refer to Page:

Use the power supply within the

Power supply

permissible power supply specifications of the high power factor conve rter .

Earth leakage circuit breaker or no-fuse breaker

Magnetic contactor

Reactor 1 FR-HCL01

External box FR-HCB

Reactor 2 FR-HCL02

High power factor converter

The breaker should be selected with care since a large inrush current flows in the high power factor converter at power on.

Install the magnetic contactor to ensure safety. When installed, do not use it to start or stop the inverter. It might reduce the high power factor converter life.

Make sure that the reactor has a proper capacity which matches the high power factor converter capacity.

Make sure that the external box has a proper capacity which matches the high power factor converter capacity.

Make sure that the reactor has a proper capacity which matches the high power factor converter capacity.

Install and wire the equipment correctly. Note: Do not install a no-fuse breaker

(NFB) across terminals P -P and N-N of the high power factor converter and the inverter.

Ground

Inverter

Devices connected to the output

Motor

Ground

Make sure that the inverter is compatible with the FR-HC. Connect the inverter suitable for the capacity of the high power factor converter.

Do not connect a power capacitor, surge suppressor or radio noise filter to the output side.

Note: When installing a no-fuse

breaker (NFB) on the output side, contact the NFB manufacturer for selection of no-fuse breaker.

Connect the motor suitable for the capacity.

To prevent an accidental electric shock, always ground the high power factor converter, external box, inverter and motor.

Instruction manuals of the devices connected on the output side

Inverter instruction manual

- 6 -

1.2 STRUCTURE

This section covers the structure, installation and removal of the equipment. In this manual, equipment parts are described with the following names.

1.2.1 Structure

The high power factor converter models have the following parts as shown below. For the location of the charge lamp, refer to “Terminal block arrangement” on page 60.

FR-HC-7.5K/H7.5K

Chassis

Accessory cover

When using the parameter unit, re- move this accessory cover and install the parameter unit in this position.

Capacity plate

Rating plate

Front cover

Cooling fan

Cooling air

Capacitors

FR-HC-15K/H15K

Cooling air

Cooling fan

Accessory cover

When using the parameter unit, remove this accesso ry cover and inst all the parameter unit in this position.

Front cover

Capacity plate

Rating plate

Front cover installation screws

Chassis (Plastic)

FR-HC-30K, 55K/H30K, H55K

Accessory cover

When using the parameter unit, remove this accessor y cover and instal l the parameter unit in this position.

Front cover Capacity plate

Rating plate

Front cover installation screws

Note:Dimensions vary with the capacity . F or full information, refer to “Outline Dimension Drawings” on page 61.

- 7 -

1.2.2 Removal and reinstallation of the front cover

FR-HC-7.5K/H7.5K

• Removal

• Reinstallation

Catch

Socket

1) Hold both sides of the front cover top.

2) Pull the cover toward you. The cover may be removed with the parameter unit on.

1) Fit the sockets at the cover bottom onto the

catches of the inverter.

2) Using the c atche s as supp orts, securely pr ess the cover against the inverter. The cover may be reinstalled with the parameter unit on.

- 8 -

FR-HC-15K/H15K

• Removal

• Reinstallation

1) Remove the two installation screws at the bottom of the front cover.

2) Hold both ends of the front cover bottom and pull the cover toward you

1) Fit the catches on t he inside of the front cover top into the sockets of the inverter.

2) Securely press the cover against the inverter.

Socket

Catch

3) Fix the cover with the bottom installation

screws.

- 9 -

FR-HC-30K, 55K/H30K, H55K

• Removal

• Reinstallation

1) Remove the front cover installation screws.

1) Attach the front cover with the installation

screws.

Note: 1.Fully check that the front cover has been reinstalled securely.

2.The serial numbe r is printed on bot h the capacity plate o n the front cover and the rating plate on the high power factor converter side face. Before reinstalling the front cover, check the serial numbers are the same. Example:

Capacity plate A46152 Rating plate A46152 001

3-digit serial number

If the high power factor converter surface is stained with fingerma rks, oil, et c. dur ing removal and/or rei nstallation work, gently clean it with a cloth soa ked with a neutral detergent or ethanol.

Note: 1.Do not use any solvent, such as acetone, benzene,

toluene and alco hol, that will cause the hig h power factor converter surface to dissolve and the paint to peel.

2. Do not clean the lens of the high power factor converter’s power lamp with a detergent or alcohol.

- 10 -

1.2.3 Removal and reinstallation of the accessory cover

To ensure safety, remove and reinstall the accessory cover after switching the power off.

• Removal

1) As in the re moval of the parameter unit, h old down the top and pull the accessory cover toward you, using the catch as a support.

Catch

• Reinstallation

1) After fitting th e fixing hole onto t he ca tch of the cover, push it into the inverter.

Fixing hole Catch

- 11 -

1.2.4 Removal and reinstallation of the parameter unit (FR-PU02)

To ensure safety, remove and reinstall the parameter unit after switching the power off.

Removal

1) Hold down the top button of the parameter unit and pull the parameter unit toward you, using the catch as a support.

Catch

Reinstallation

• Direct installation onto the high power factor converter

1) After fitting the fixing hole of the parameter unit (PU) on the catch of the cover, confirm the

Fixing hole Catch

connector position and push the parameter unit into the inverter, using the catch as a support.

• Installation using the cable (FR-CBL )

1) Securely inser t one connector of the cable into the connector of the high power factor converter and the other cable connector into

Installation screws

the PU connector. Insert the cable connector along the guides. (If the orientation is incorrect, the high power factor converter may be damaged.)

2) After plugging the cable connector into the high power factor converter connector, fix it

Guide

securely with the in stallation screws.

Note: 1.The parameter unit must only be installed on the high power factor converter when t he front cover

is fitted.

2.During installation, do not apply force to the display (liquid crystal).

- 12 -

1.3 INSTALLATION AND WIRING

1.3.1 Precautions for installation (1) Installation of the high power factor converter

Instructions for ambient temperatures

The lives of the high power factor converter and reactors 1, 2 are affected considerably by ambient temperatures. Keep their ambient temperatures below the permissible value (50°C). Measure the ambient temperatures in the following positions to make sure that they are within the permissible range.:

Measurement position

5cm

FREQROL

Measurement position

Note: 1.When the high power factor converter is

installed in a panel, determine the cooling method and panel dimensions so that the ambient temperature of the high power factor converter is within the permissible range (specified value is given on page 56).

2.When the inverter and high power factor converter are installed in the same panel or a ventilation fan is mounted in the panel, extreme care must be taken to keep the ambient temperatures of the high power factor converter and inverter below the permissible value. If the high power factor converter, inverter and/or ventilation fan is installed in an improper position, the ambient temperature of the high power factor converter will rise and ventilation effects will reduce.

5cm

Leave sufficient space around the equipment.

For adequate heat dissipation, leave sufficient space around the high power factor converter.

5cm or more

10cm or more

FREQROL

10cm or more

5cm or more

Leave sufficient clearances ab o ve and under the u nit to ensure proper ventilation.

Cooling fan built in converter

Cooling air

It is possible to place the heat sink outside the enclosure to grea tl y reduce heat generated.

Inside enclosure

High power factor converter

Enclosure

Mounting bracket FR-ACN (option)

Heat sink

Cooling fan

Inverter Converter

Built-in cooling fan

(Correct) (Incorrect)

Inverter

Converter

Installation of Converter and Inverter

Ventilation fan

Converter Converter

(Correct) (Incorrect)

Position of Ventilation Fan

Cooling air

Note: 1. Use the optional mounting bracket (FR-ACN)

(see page 70). The mounting area should be machined to the panel cutting dimensions on page 66.

2.The cooling section outside the panel has a cooling fan. Do not use the inverter in damp, oil mist or dust environments.

- 13 -

Bolt the unit sec u re ly and verticall y.

Install the un it on a non-combustible surface.

Install the high power factor converter on a surface securely and vertically (so that the letters FREQROL are located at the fro nt) with screws or bolts.

Note: Hor izontal or side inst allation may cause the

high power factor converter to fail. Always install the unit vertically.

Install the high power factor converter on a noncombustible. If it is installed directly on or near a combustible, a fire may take place.

Avoid places where the equipment is subjected to oil mist, flammable gases, fluff , dust, dirt, etc.

Install the unit in a clean place or inside an “enclosure” which does no t accept any suspended matter.

Located at front

Install the inverter where it is not subjected to vibration.

Also take the vibration of a trolley, press, etc. into consideration.

Avoid high temperature and high humidity.

Avoid direct sunlight, heat and humidity.

- 14 -

(2) Installation of the reactors 1, 2 and external box Confirm th e types.

Note the types of the reactor 1 (FR-HCL01) and reactor 2 (FR-HCL02) look alike in outline.

Reactor 1 (FR-HCL01)

AC REACTOR TYPE FR-HCL01 BKO-CA SERIAL

Reactor 2 (FR-HCL02)

AC REACTOR

(Note)

Note: For the reactor 1 (FR-HCL01) and reactor 2 (FR-

TYPE FR-HCL02 BKO-CA SERIAL

HCL02), check the “TYPE” in the above rating plates.

(Note)

Avoid places where the equipment is subjected to oil mist, flammable gases, fluff , dust, dirt, etc.

Install the equipment in a clean place or protect them from suspended matter.

Bolt the reactors securely and horizontally.

To prevent looseness, install the reactor 1 (FRHCL01) and reactor 2 (FR-HCL02) on a surface securely and horizontally with screws or bolts.

Note:Avoid vertical or side installation and install

them on a mounting stand which can withstand their weights.

Instructions for ambient temperatures

For adequate heat dissipation, leave sufficient space around the reactor 1 (FR-HCL01) and reactor 2 (FR-HCL02).

10cm or more

5cm or more5cm or more

Install the equipment on a non-combustible surface.

Install the reactor 1 (FR-HCL01) an d reactor 2 (FRHCL02) on a non-combustible. Direct install ation on a combustible may cause a fire.

Install the external box (FR-HCB) vertically. Note:Install it vertically. Horizontal or side

installation may lead the external box to a failure.

Note:Since the charged sections of the reactor 1,

reactor 2 and external box are uncovered, fully protect them to prevent ground fault and electric shock.

- 15 -

1.3.2 Wiring instructions

During wiring, d o no t l eave wire off-cut s i n t he high power fact or converter and external bo x.

Wire offcuts will cause a mal func ti on, failure or fault. The high power factor converter should always be kept clean.

Wire offcuts, etc.

Use the space on the left-hand side of the main circuit terminal block to run the control circuit cable.

Control circuit terminal block

Before starting wiring or inspection, switch power off, make sure that the converter LED indicator has gone off, wait for at least 10 minutes after the charge lamp on the printed circuit board has gone off.

For some short time after power-off, there is a dangerous voltage in the capacitor. Start work about 10 minutes after ensuring that the charge lamp is off.

When the power supply voltage is special for the high power factor converter (the rated input voltage is exceeded), change the connection of the jumper in the internal transformer. (FR-HC-H7.5K H15K, H30K, H55K)

If the connection is not changed, the 400V class high power factor converter may be heated, resulting in fault or burnout. For the FR-HC-H7.5K, change the connection of the jumper in the interna l transform er in the externa l box.

Main circuit terminal block

Cable

Cut off the wiring cover (protective bush) windows using nippers or a cutter when running the cables. (FR-HC-7.5K/H7.5K)

Wiring cover

Nippers

Cut off.

Protective bush

Do not apply a voltage directly to the alarm output signal terminals (A, B, C).

Always apply a voltage via a relay coil, lamp, etc. to these terminals.

380 to 460V

The cable size for connection to the control

circuit terminals should be 0.75mm

If the cable size used is 1.25mm

or less.

or more, the front cover may expand, resulting in a co ntact fault of the parameter unit. This fault is indicated by the following message displayed on the parameter unit and disables operation from the parameter unit. Run the cables so that they do not occupy much of the control box terminal block space.

Parameter unit display

PU to Inverter

comms. Error

Inv. Reset ON

Use shielded or twisted cables for connection to the control circuit terminals.

Voltage

Run them away from the main and power circuits (such as the 200V relay sequence circuit).

A B

Note:Connect the sheath of the shielded cable to

terminal SD.

- 16 -

1.3.3 Wiring of the main circuit

• The high power factor converter (FR-HC) is a high-power factor, low-noise inverter option unit designed for use with the transistorized inverters (FR-HC compatible models) in accordance with the harmonic suppression guidelines published by Ministry of Economy Trade and Industry (formerly Ministry of International, Trade and Industry). This high power factor converter is used for the suppression of harmonics to an input power supply.

• To comply with the harmonic suppression guidelines published by the MITI, the system needs to be configured as indicated and make sure that terminals P and N are sacurely connected to terminals P and N of the inverter. An incorrect connection will cause th e high power factor converter to display an alar m or to be faulty or damaged.

• Refer to the inverter instruction manual on how to wire the system to suppress har monics to the input power supply. Especially note the wiring distance and cable size.

(1) Cable, Crimping terminals etc.

The following table lists the cables and crimping terminals used for each of the devices of the High power factor converter system and the torques for tightening the screws:

Cables

P, N

AWG *1mm

R4, S4,

P, N

Type

Terminal

screw

size

Tightening

torque

m *3

Crimping

terminal *2

R4, S4,

P, N

R4, S4,

FR-HC-7.5K M4 1 8-4 8-4 8 8 8 8 6 6

FR-HC-15K M6 4 22-6 22-6 22 22 4 4 16 16 FR-HC-30K M8 7 60-8 60-8 60 60 1/0 1/0 50 50

FR-HC-55K M12 24 150-12 150-12 150 150

MCM

300

MCM

300

FR-HC-H7.5K M4 1 3.5-4 3.5-4 3.5 3.5 12 12 4 4

FR-HC-H15K M6 4 8-6 8-6 8 8 8 8 10 10 FR-HC-H30K M6 4 22-6 22-6 22 22 4 4 25 25 FR-HC-H55K M8 7 60-8 60-8 60 60 1/0 1/0 50 50

PVC insulated

Cables

2 *

R4, S4,

P, N

––

PVC insulated

Cables

2 *

Type

Terminal

screw

size

Tightening

torque

m *3

Crimping

terminal *2

R2, S2, T2R3, S3, T3R2, S2, T2R3, S3, T3R2, S2, T2R3, S3, T3R2, S2, T2R3, S3,

Cables

AWG *1mm

FR-HCB-7.5K M5 2 8-5 8-5 8 8 8 8 6 6

FR-HCB-15K M5 2 22-5 22-5 22 22 4 4 16 16 FR-HCB-30K M6 4 60-6 60-6 60 60 1/0 1/0 50 50

FR-HCB-55K M8 7 150-8 150-8 150 150

MCM

300

MCM

300

––

FR-HCB-H7.5K M5 2 3.5-5 3.5-5 3.5 3.5 12 12 4 4

FR-HCB-H15K M5 2 8-5 8-5 8 8 8 8 10 10 FR-HCB-H30K M5 2 22-5 22-5 22 22 4 4 25 25 FR-HCB-H55K M8 7 60-8 60-8 60 6 0 1/0 1/0 50 50

PVC insulated

Cables

2 *

R, S, T

R2, S2,

Type

Terminal

screw

size

Tightening

torque N

m *3

terminal *2

R, S, T

Crimping

R2, S2,

R, S, T

R2, S2,

Cables

AWG *1mm

R, S, T

R2, S2,

FR-HCL01-7.5K M5 2 8-5 8-5 8 8 8 8 6 6

FR-HCL01-15K M6 4 22-6 22-6 22 22 4 4 16 16 FR-HCL01-30K M8 7 60-8 60-8 60 60 1/0 1/0 50 50

FR-HCL01-55K M12 24 150-12 150-12 150 150

MCM

300

MCM

300

––

FR-HCL01-H7.5K M4 1 3.5-4 3.5-4 3.5 3.5 12 12 4 4

FR-HCL01-H15K M5 2 8-5 8-5 8 8 8 8 10 10 FR-HCL01-H30K M6 4 22-6 22-6 22 22 4 4 25 25 FR-HCL01-H55K M8 7 60-8 60-8 60 60 1/0 1/0 50 50

- 17 -

Cables PVC insulated Cables

AWG *1mm

2 *

Type

Terminal

screw

size

Tightening

torque

m *3

Crimping

terminal *2

R3, S3, T3R4, S4, T4R3, S3, T3R4, S4, T4R3, S3, T3R4, S4, T4R3, S3, T3R4, S4,

FR-HCL02-7.5K M5 2 8-5 8-5 8 8 8 8 6 6

FR-HCL02-15K M6 4 22-6 22-6 22 22 4 4 16 16 FR-HCL02-30K M8 7 60-8 60-8 60 60 1/0 1/0 50 50

FR-HCL02-55K M12 24 150-12 150-12 150 150

MCM

300

MCM

300

––

FR-HCL02-H7.5K M4 1 3.5-4 3.5-4 3.5 3.5 12 12 4 4

FR-HCL02-H15K M5 2 8-5 8-5 8 8 8 8 10 10 FR-HCL02-H30K M6 4 22-6 22-6 22 22 4 4 25 25 FR-HCL02-H55K M8 7 60-8 60-8 60 60 1/0 1/0 50 50

Note: *1.The cable used should be 75°C copper cables.

*2.Use the UL approved round crimping terminals. Crimp the terminals with the crimping tool

recommended by the terminal manufacturer.

*3.Tighten the terminal screws to the specified torques. Undertigtening can cause a short or misoperation.

Overtigtening can cause the screws and unit to be damaged, resulting in a short or misoperation.

*4.This column is for Low Voltage Directive.

(2) Wiring example (FR-A500 series)

The wiring method varies with the inverter series.

Reactor 1

(FR-HCL01)

External box

(FR-HCB)

Resistor

MC1 MC2

Reactor 2

(FR-HCL02)

High power factor converter

(FR-HC) MC1 MC2

Inverter (FR-A500 series) R

(Note 4)

Power supply

NFB MC

1) R

S T

R2 S2 T2

Resistor

Filter capacitor

3) 4) 5)

R3 S3 T3

R4 S4

R S T

R1 S1

RDY RSO

Y1 or Y2

(Note 8)

(Note 9)

N X10

(Note 5)

RES X11

(Note 5)

(Note 7)

Note: 1.Use care to minimize the wiring distance between respective terminals.

2.Before starting wiring, cover the top ventilation hole to prevent wire offcuts from entering.

3.Use the ground terminal to ground the equipment securely.

4.Keep the inverter’s power input terminals R, S, T open. The i nverter will be damaged if they are connected accidentall y. Also, opposite polar ity of term inals P, N will damage the high power factor converter and inverter.

5.The terminals used with the X10, X11 signals require their functions to be set. (Refer to the inverter instruction manual for details.)

6.Match the power supply phases before connecting terminals R4, S4, T4 and terminals R, S, T.

7.A different power supply may be supplied to terminals R1 and S1.

8.Keep the high power factor converter’s terminals R1, S1 unconnected.

9.Do not insert the NFB between terminals P-N (P-P, N-N).

10.The R, S , T terminals of the high pow er factor converter (FR-HC) must be connected to the po w er supply. Running the inverter without connecting the terminals to the power supply will damage the high power factor converter (FR-HC).

Motor

V W

CAUTION

Confirm the connection sequence of the reactors 1 and 2. Incorrect connection will make

them abnormally hot.

- 18 -

1) Wiring the power supply and reactor 1

Power supply

NFB

Reactor 1

RR2S S2T T2

RS T

Power supply

FR-HCL01-55K appearance (Note 2)

The cable size is dependent on the capacity of the high power factor converter. (Refer to page 17.)

Note: 1.Use the magnetic contactor (MC) and reactor 1 which match the high power factor converter capacity.

(Refer to page 62.)

2.Note that the FR-HCL01-55K is different in outline and terminal positions.

2) Wiring the reactor 1 and external box

Reactor 1 External box

R2 S2 T2

R3 S3 T3

Reactor 1

Overall wiring distance: Within 10m

Transtormer

Capacitor

R2 T2

Magnetic

Resistor

contactor

S3R3 T3

FR-HCL02

MC1.MC2

FR-HC

Resistor

Terminal block

Note: 1.The cable size is dependent on the capacity of the external box. (Refer to page 17.)

2.The reactor generates heat. When installing the reactor, exercise care not to heat the external box.

3.Run the cables to keep the reactor untouched by the sheaths of the cables.

- 19 -

3) Wiring the external box and reactor 2

(Overall wiring distance should be not more than 10m.)

External box Reactor 2

S2 T2

S3 T3

Overall wiring distance: Within 10m

Reactor 2

Resistor

Note: The cable size is dependent on the capacity of the reactor. (Refer to page 17.)

4) Wiring the reactor 2 and high power factor converter

(Overall wiring distance should be not more than 10m.)

Power supply

FR-HCL01

Capacitor

R2 T2

Magnetic contactor

S3R3 T3

Transtormer

Resistor

Terminal block

MC1.MC2

FR-HC

Reactor 2

High power factor converte

R4 S4 T4PN

R3 R4 S3 S4 T3 T4

Reactor 2

High power factor converter

Screw size

R1 S1

RSTR4S4T4

Charge lamp (yellow)

Note: The cable size is dependent on the capacity of the reactor. (Refer to page 17.)

5) Example of how to wire the high power factor converter and inverter (FR-A500 series)

These units should be connected to transmit commands from the high power factor converter to the inverter securely. The cable size varies with the inverter series. Refer to the inverter instruction manual for wiring instructions. (Overall wiring distance should be not more than 50m.)

High power factor converter

P N

RDY

Control circuit

RSO

Y1 or Y2

P N

X10 RES X11

Inverter

(Note 3)

Cable size: 0.75 to 2 mm

- 20 -

Note: 1.The high power factor converter (FR-HC) operates as a common conver ter. Use terminals P, N to

connect it with the inverter. Always keep the inverter’s power input terminals R, S, T open. If they are connected accidentally, the inverter will be damaged. Opposite po larity of terminals P, N will damage the inverter and high power factor converter.

2.The size of the cables for connecti on of terminals P, N should be the same as that use d in the power supply side of the inverter. (Refer to the inverter instruction manual.)

3.Refer to the inverter instruction manual for the invert er terminal to be c onne cted to termi na l R DY of the high power factor converter.

4.Do not insert the NFB between terminals P-N (P-P, N-N).

6) Wiring the reactor 1 and high power factor converter

Supply power to the power detecting terminals (R, S, T) independently of the main circuit wiring.

High power factor converte

contro l ci rcuitReactor 1

S T

Power supply

Reactor 1

R S T

High power factor converter

control circuit terminals

Overall wiring distance: Within 10m

Cable size: 1.25mm

Note: 1.Ter minals R, S, T of the high power factor converter (FR-HC) are control terminals designed to

detect power supply phases. Be fore wiring, it is necessar y to match the phases of ter minals R4, S4, T4 with those of terminals R, S, T. If wiring is inc orrect, the high power factor converter (F RHC) will not operate properly.

2.The R, S, T terminals of the high power factor converter (FR-HC) must be connected to the power supply. Running the inverter without c onnecting the terminals to the power supply will damag e the high power factor con verter (FR-HC).

7) Wiring the power supply and inverter

Supply power to the inverter independently of the high power factor converter (FR-HC).

Terminal block for control circui

Pull out.

NFB

Power supply

Cable size:0.75 to 2mm

Inverter control power supply

R1 S1

1) Loosen the upper screws.

2) Remove the lower screws.

3) Pull out the jumpers toward you and remove.

4) Conncet the cables of the other control circuit power supply to the lower terminals (R1, S1).

5) Tighten the upper screws without fail.

Note: 1.Remove the jumpers across terminals R-R1 and S-S1 of the inverter control circuit.

2.Always connect the power supply to the inver te r wh ic h has the alternate power supply inp ut terminals R1, S1. Power for the inverter’s control power and large-capacity cooling fan (200V 15K or more/ 400V 11K or more) will be supplied. Otherwise the inverter may come to an alarm stop or be damaged. Refer to the inverter instruction manual to check whether the inverter has the alternate power supply input terminals or not.

- 21 -

8) Wiring the external box and high power factor converter

Power supply

FR-HCL01

Capacitor

R2 T2

S3R3 T3

FR-HCL02

External box

MC1 MC2

Cable size: 0.75 to 2mm

High power factor converter

MC1 MC2

Resistor Magnetic contactor

Transformer

Resistor

Terminal block

MC1.MC2

High power factor converter

Control circuit terminal block

RSTR4S4T4

Overall wiring distance: Within 10m

Screw size

R1 S1

Note:Ter minals MC1, MC2 of the high power factor converter provide contro l signals for the inrush cur rent

control circuit within the exter nal box. Always connect these ter minals with the external box. Otherwis e, the external box’s internal circuit will be damaged.

Notes for grounding

• The high power factor converter lea ks cur rent. To prevent an electric shock, always ground the converter before starting operation (200V class: class D grounding, grounding resistance 1 00 maximum, 400V class: class C grounding, grounding resistance 10 maximum).

Ω

• To ground the hi gh power factor converter, use the exclusive ground termina l. (Do not use the screws in the casing, chassis, etc.)

• Use the thickest and shortest possible ground cable that is equal to, or larger than the size indicated in the right table. Ground the high power factor converter at a point ne arest to itself and the inverter.

High power factor

converter capacity

Ground cable size

200V class 400V class

7.5kW 5.5 3.5 15kW 14 8 30kW 22 14 55kW 38 22

(Unit:mm2)

Grounding

- 22 -

(3) Application of the high power factor converter and inverter

1) When one inverter is connected to the hig h power factor converter, the capacities of the inverters that may be connected are as listed in the following selection table. : indicates that the high

power factor converter and inverter may be used together. –: indicates that they cannot be used together. (Note)

Motor capacity (kW) 2.2 or less 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55

Inverter capacity (K) 2.2 or less 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55

FR-HC-7.5K –

FR-HC-15K –––

0 0

FR-HC-30K – ––––

FR-HC-55K – ––––––– FR-HC-H7.5K –

FR-HC-H15K –––

0 0

FR-HC-H30K – ––––

FR-HC-H55K – –––––––

Outside application range

Note: When the invert er connected has a capacity less tha n in the application range, the high power

factor converter may be used as a common conver ter or regenerative converter, but its capability to suppress power harmonics will reduce.

(4) Connection of more than one inverter to the high power factor conve rter

Up to six inverters may be connected to one high power factor converter. (Do not connect seven or more inverters.) The capacity of the high power factor converter should always be higher than the sum of those of the inverters connecte d. Also, one inverter connected should have a capacity more than half of the high power factor converter capacity.

Note: Note that if the sum of the inver ter capacities is less than half of the high power factor converter

capacity, the high power factor converter may be used as a common conver ter or regenerative converter, but its capability to suppress power harmonics will decrease.

1)For connection of more than one inverter, select the cable size carefully beca use the inverter termin als

P, N will be wired us ing junction ter mina ls or jumpers. Select the cable size so that inverter capacities are added in order, beginning with the farthest inverter.

2)For connection of more than one inverter, connect them in sequence of larger capacities.

3)Specific example

FR-HC

55K

A520

30K

A520

15K

A520

5.5K

A520

2.2K

First: 125mm

Second: 15+5.5+2.2+1.5+0.75=24.95K Hence, capacity is 30K, so 50mm

Third: 5.5+2.2+1.5+0. 75=9.95K Hence, capacity is 11K, so 14mm

Fourth: 2.2+1.5+0.75=4.45K Hence, capacity is 5.5K, so 5.5mm

cable from FR-HC capacity

cable is selected.

A520

1.5K

A520

0.75K

Fifth: 1.5+0.75=2.25K Hence, capacity is 2.2K, so 2mm

Sixth: 2mm

cable from 0.75K

cable is selected.

Note: When the FR-E500, FR-A024 series inverters are connected to the high power

factor converter (FR-HC-7.5K), at least one of the inverter connected is required t o be at least half the ratin g of the high power factor rating. In this case, at least one of the inverter connected is 3.7K or greater.

- 23 -

(5) Where the power supply is special (rated input voltage is exceeded) for the 400V class high

power factor converters (FR-HC-H15K, H30K, H55K, FR-HCB-H7.5K)

Change the connection of the j um per to the internal transfor me r a ccor ding to t he op erating power supply voltage. For the FR-HC-H7.5K, change the connection of the internal transformer inside the external box.

Operating power supply voltage range vs. jumper position

Jumper Position

323V(380V-15%)

456V(415V+10%)

342V(380V-15%)

484V(440V+10%)

391V(460V-15%)

506V(460V+10%)

Operating Power Supply Voltage

50Hz 60Hz

As on the left

342V(380V-10%)

506V(460V+10%)

As on the left

Remarks

Factory setting

Note: Change the jumper position acco rding to the operatin g power supply. Otherwise the high power

factor converter will be heated and may become faulty or burn out.

Changing the jumper position

• Model: . . . . FR-HC-H15K, FR-HCB-H7.5K

Terminal symbol cover

Pull out.

Jumper

Transformer terminal block

Appearance of FR-HCB-H7.5K

1) Remove the mounting screws of the terminal symbol cover and remove the cover.

2) This reveals the termi nal block of the inter nal transform er. After removing the screws from the jumper in the terminal block, reconnect the jumper in accordance with the operating voltage in the above table.

• Model: . . . . FR-HC-H30K, H55K

Terminal cover

1) Remove the terminal cover of the internal transformer located under the main circuit terminal block (R, S, T).

2) Remove the screws from the jumper in the terminal block, and reconnect the jumper.

Jumper

Transformer terminal block

- 24 -

(6) Installation and wiring example

Inverter

N P

U V W

R S T

MC1

HCB

MC1

Converter

(FR-HC)

MC2

N P

Motor

1) Leave clearances of at least 10cm above and below and 5cm o n the left and right side of each unit.

2) Up to six cables may be bundled.

3) Install par titions to shut off heat given to the upper units.

4) The reactors generate heat. Run cables away from them.

5) When the installation place has enough space, it is recommended to install the units side by side.

Power supply

NFB

HCL01

HCL02

(Note 4)

Main circuit High-voltage control circuit

Low-voltage control circuit

- 25 -

1.3.4 Wiring of the control circuit

) ) ) ) )

)

Control input signals (voltage input disabled)

(Note)

(For terminal block functions, refer to “Terminals” on page 58.)

Output signals

Alarm output (1 change-over contact output)

Open collector

output common

Multi-purpose

output terminal

Multi-purpose

output terminal

Open collector outputs

Overload alarm Converter reset

Converter operating

Inverter operation

Meter connection

common

Meter connection

Contact input common

Monitor switching Monitor switching

Converter stop

External transistor common

enable

Reset

(NC) (NC) (NC) (NC)

(NC) (NC) (NC)

SE Y2 Y1

OL RSO CVO

RDY

SOF RES

A B

High power factor converter

RDY CVO RSO

OL V1 Y2 SE

Powe suppl 24V o 12VD

Note: A voltage applied in the wrong

direction will damage the high power factor converter. Beware of miswiring such as the direction of diode connection.

(NC)

(NC (NC (NC (NC (NC

(NC

Note: 1.Terminals SD and SE are common to the I/O signals and are isolated from each other. Do not

earth (ground) .

2.Use shielded or twisted cables for connection to the control circuit terminals and run them away from the main and power circuits (including the 200V relay sequence circuit).

3.Since the control circuit input signals are micro currents, use two parallel micro signal contacts or a twin contact to prevent a contact fault.

4.Keep the free termina ls ( NC) unc on nected. Otherwise, the high power factor converter may become faulty.

5.When connecting two crimping terminals to one of the control circuit terminals, round or square open-ended crimping terminals of the size as shown on t he r igh t s hou ld be use d b ack to ba ck.

Do not use the free terminals (NC) of the control circuit. Using them will lead to the

failure of the high power factor converter and inverter.

Steep distortion or sinking in power may cause the reactor 2 (FR-HCL02) to generate

unusual noise. This phenomenon occurs due to a power fault and is not attributable to

a damaged high power factor converter (FR-HC). When the load is light, harmonic suppression effects will decrease. Be sure to connect terminal RDY of the FR-HC to the X10 or MRS signal assigned

terminal of the inverter, and connect terminal SE of the FR-HC to terminal SD of the

inverter. Without proper connecting, FR-HC will be damaged.

Nominal

1.25-3

Note: Round crimping terminal V1.25-MS (Japan Solderless Terminal)

B(mm)

6.4 or less

F(mm)

53 or more

CAUTION

- 26 -

Using the PC terminal

This termi nal is used to connect transistor output (open coll ector output) such as a pr ogrammable controller (P C). Connecting the external power supply common for transistor outpu t to the PC terminal prevents a faulty operation caused by a sneak current. (The power supply voltage of the PC terminal should be 24VDC.)

Instruction for contact inputs

AY40 transistor output module

24V

SOF

RES

High power factor converter

24V (SD)

AY40 transistor output module

SOF

RES

24V

High power factor converter

DC 24V

(SD)

The AY40 module requires a 24VDC power supply.

Since input signals to the control circuit are at a low level, use two parallel micro signal contacts or twin contact for contact inputs to prevent a contact fault.

Micro signal contacts

- 27 -

Twin contact

Wiring example for commercial power supply-inverter switchover

• Complicated sequence circuit for commercial power supply-inverter switch-over The following example shows wiring for connection of a commercial power supply. (FR-A500 series) When making connection, always provide interlocks between magnetic contactors MC2 and MC3:

MC2

NFB MC1

Power supply

Reactor 1

(FR-HCL01)

R S T

R2 S2 T2

External box

(FR-HCB)

R2 S2 T2

Filter capacitor

Resistor

MC1 MC2

R3 S3 T3

Reactor 2

(FR-HCL02)

R3 S3 T3

converter (FR-HC) MC1 MC2

R S T

R1 S1

High power fa ct or

RDY RSO

Y1 or Y2

(Note)

Inverter (FR-A500 series) R

S T

N X10

RES X11

R1 S1

MC3

Motor

Note: Keep the high power factor converter’s terminals R1, S1 unconnected.

- 28 -

2. PARAMETERS

This chapter presents details on the “parameters” of this product. Always read the precautions, etc. before starting use.

2.1 PARAMETER UNIT.................................................................................... 29

2.2 PARAMETER FUNCTION DETAILS .......................................................... 31

2.3 HELP FUNCTIONS........................ ............................................ .. .............. 40

2.4 CONVERTER RESET................................................................................ 43

2.1 PARAMETER UNIT

The parameter unit (FR-PU02E-1) is installed directly to the high power factor converter or connected to it by the cable (FR-CBL) to allow parameters to be set and data to be monitored. Note that as compared to the inverter, there are restrictions on functions. In this manual, the parameter unit may be referred to as the PU.

2.1.1 Structure of the parameter unit

Help key

• Used to call the help selection screen.

• Note that there are restrictions.

Clear key

• Used to clear a set value entered.

• Used to return to the help

selection screen when you have selected an invalid help item.

Shift key

• Used to shift to the next item in the setting or monitoring mode.

Numeral keys

• Used to enter the parameter number and set value.

FR-PU02E

PARAMETER UNIT

-1

Display

• Shows the monitor screen, etc.

Mode selecton keys

• Used to select the setting mode and monitoring mode. The “EXT OP” and “PU OP” keys are invalid.

Frequency change ke ys

• On the monitoring, parameter or help item selection screen, these keys are used to move the cursor. Hold down the SHIFT key and press either of these keys to advance or return the display screen one page.

Read key

• Used also as a decimal point key.

• Acts as a key to select or read any of various functions.

PU main monitor

• Three different monitors can be select ed in sequence with the [SHIFT] key.

POWER ALARM

FR-PU02E

-1

Operation command key s

• Invalid.

Write key

• Used to write a set value in the setting mode, etc.

Converter LED display

• POWER (yellow) indicates whether power is supplied or not and ALARM (red) indicates whether alarm output is provided or not.

Overload signal detecting indication

Display unit

Indicates the driving (FWD) or re

enerative (RV) mode.

- 29 -

2.1.2 Setting and changing the parameter values

The high power factor converter has many parameters. Using the PU, the required parameters can be selected and their values set and/or changed as appropriate according to the running conditions. For more information, see the “Parameter List” (page 31). Set “1” in Pr. 77 “parameter write disable” to disable write. (See page 37.)

• Operation procedure (Readin g and writing the value of Pr. 22 “overload signal detection level”)

1) Press the [SET] key. . . . . . The parameter setting

mode is entered.

2) Enter the intended

parameter number [2][2].

. . . . . The screen on the right

is displayed.

3) Press the [READ] key . . . . . . The current set value is

shown on the display.

4) Enter the required value.

(Example: To set 180 %)

. . . . . A new set value is

shown on the display.

SETTING MODE Set Pr. NO. FOR PR. List

<HELP>

SETTING MODE

Pr. NO.

<READ>

150.0%

180.0%

(Note 1)

5) Press the [WRITE] key. . . . . . The set value is stored

into memory.

180.0% Completed

6) Press the [SHIFT] key to move to the next parameter (Pr. 40) and call the current set value. Then, press the [SHIFT] key to advance to the next parameter.

Display

FR-PU02E

-1

PARAMETER UNIT

3) 5)

Note 1:If a setting error has o ccur red during the entry of a set value, press the [C LEAR] key to return to

the status before that set value was entered.

- 30 -

2.2 PARAMETER FUNCTION DETAILS

2.2.1 Parameter list

Function

–

Standard operation

function

Multi-

function

output terminal function

Parameters

Display

functions

Automatic

restart

function

Operation

selection functions

Calibra-

tion func-

tions

Parameter

No.

1 Power supply frequency 1 (Note1) ––60.00Hz – 2 Power supply frequency 2 (Note1) ––50.00Hz –

22 Overload signal detection level 0 to 200% 0.1 150.0%

40 Output terminal assignment 0 to 33 (Note 6) 1 1

51 Input power monitoring reference 0 to 100kW 0.1 52 PU main display data selection 0 to 3333 (Note 7) 1 123 53 Input voltage monitoring reference 0 to 500.0V 0.1 54 FM terminal function selection 0 to 3333 (Note 7) 1 123 55 Bus voltage monitoring reference 0 to 1000.0V 0.1

56 Current monitoring reference 0 to 500.00A 0.01

57 Restart selection 0, 9999 1 9999

65 Retry selection 0, 1, 2, 3 1 0 67 68 Retry waiting time 0.1 to 360.0 s 0.1 s 1.0 s

69 Retry count display erasure 0 – 0 77 Parameter write disable selection 1, 2 1 2

145 Parameter unit language switching 0, 1, 2, 3 1 0 900 FM terminal calibration –––

Number of retries at alarm occurrence

Name Setting Range

0 to 10, 101 to 110 1 0

Minimum

setting

Increment

Factory Setting

Rated power

(Note 2)

220V/400V

(Note 3)

340V/680V

(Note 3)

Rated current

(Note 5)

Customer

Setting

Note: 1.You cannot set or c hange the values of Pr.1 “power supply frequency 1” and Pr. 2 “power supply

frequency 2”.

2.This set value varies with the capa city of the high power factor converter and is factory-set to the rated power of the corresponding capacity.

3.These set values vary with the rated voltage of t he high power factor converter and is factory-set according to the 200V/400V class.

4.The set values of the half-tone scree ned parameters can be changed if “1” ( write di sable) is set in Pr. 77 “parameter write disable selection”.

5.This set value varies with the capa city of the high power factor converter and is factory-set to the rated current of the corresponding capacity.

6.Use numerals 0 to 3 to set a two-digit value in Pr. 40 “output terminal assignment”.

7.Use numerals 0 to 3 to set a four-digit value in Pr. 52 “PU main display data selection” and Pr. 54 “FM terminal function selection”.

- 31 -

2.2.2 Setting of parameters to improve the corresponding operational functions

Preset input frequency to the converter

To detect the overload signal

Pr.1 “power supp ly f re q uen cy 1 ”, Pr.2 “power supply frequency

2”

• Indicates that the converter is operable in the district where the power supply frequency is 50Hz or 60Hz.

Parameter Number Factory Setting

1 60.00Hz 2 50.00Hz

Pr.22 “overload signal detection level”

• If the inr ush current of the hig h power factor converter exceeds the set value of Pr. 22 “overload signal detection level”, the alarm detection signal “OL” is displayed and output from the output terminal “OL”. Set a value with reference to the rated current.

FR-PU02E

Overload signal detection signal

FW D EXT

To change the functions of the output terminals Y1, Y2

Note: The set value (%) indicates the ratio of the inr ush current to

the rated current of the high power factor converter.

Pr.40 “output terminal assignment”

• Functions can be reassigned to output terminals Y1, Y2. Set a 2-digi t inte ger in Pr. 40 “output ter minal ass ignment”. The value of each digit indi cat e s th e fun c ti on of th e co rr espon d ing te rminal.

Pr.40= First digit Second digit

Y2 Y1

Pr.40 Setting Function Name Operation

When the input power supply is in phase with the arithmetic result, the

(Factory setting)

1 Output voltage match

Power supply phase

detection signal

Instantaneous power

failure detection

Driving/regenerative

mode judgment

power supply phase detection signal is locked. When they are out of phase, the power supply phase detection signal is unlocked and output from the open collector output terminal.

When the bus voltage matches the command value from the CPU, the corresponding signal is output from the open collector output terminal.

This signal indicates that an instantaneous power failure occurred.

Whether the mode is driving or regenerative is judged. In the driving mode, the open collector terminal does not conduct.

- 32 -

Note: 1.“Output” means that the open collector outputting built-in

transistor switches on (conducts).

2.When a one-dig it value is enter ed, the u nit re cogni zes that “0” is in the first digit and te rmi nal Y2 ser ves to output the power supply phase detection signal.

To set the reference values of terminal FM

To set/change the display data on the parameter unit (terminal FM)

Pr. 51 “input power monitoring reference”, Pr. 53 “input

voltage monitoring reference”, Pr. 55 “bus voltage monitoring reference”, Pr. 56 “current monitoring reference”

• With these parameters, you can set the reference values of the power, voltage, bus voltage and current input from the power supply to the high power factor converter. Set values which are suitable for the rated values of the power supply and high power factor converter.

• These values are used as reference outputs to terminal FM.

• Parameters

Parameter

Number

Input power monitoring reference

Input voltage monitoring reference

Bus voltage monitoring reference

Current monitoring reference

Name Factory Setting

Rated power 0 to 100KW 220V/440V

(Note) 340V/680V

(Note) Rated current 0 to 500.00A

Note: These set values vary with the voltage class of the high power factor

converter and are factory-set according to the 200V/400V class.

Setting

Range

0 to 500.0V

0 to 1000.0V

Pr. 52 “PU main display data selection”, Pr. 54 “FM terminal

function selection”

• The display data of the parameter unit can be set or changed. Note that the moni tor display is not pr ovided by merely setting th e parameter. Use the switches X1, X2 to change to the monitor display.

• By setting or changing the value in Pr. 52 “PU main display data selection”, current monitoring will vary.

(1) Each digit where the Pr. 52 (Pr. 54) value is set has relationships

with the positions of terminal X1, X2 switches.

FR-PU02E

0123

First

Second

Third

digit

Parameter: Pr.52 (Pr.54) =

Terminal (switch);

digit

Fourth

digit

First digit Second digit Third digit Fourth digit

X1 OFF ON OFF ON X2

ONONOFFOFF

- 33 -

(2) The following values may be set in Pr. 52 (Pr. 54):

Pr. 52 (Pr. 54) Setting Displa y

0 Input current monitoring 1 B us voltage monitoring 2 Input voltage monitoring 3 I nput power monitoring

(3) Pr. 52 (Pr. 54) is factory-set as follows:

Parameter; Pr.52 (Pr.54) = 0(Note) 1 2 3

Since the terminals (switches) are factory-set to X1=OFF and X2=OFF, the monitor scr een on the parameter uni t shows “input current monitoring”.

Note:Basically, a four-digit value is entered in Pr. 52 (Pr. 54). “0”

set in the first of the four digits is not dis played. The factory setting of “123” is recognized as “0123”.

(4) Shift operation for PU main monitoring

Three different monitors set in Pr. 52 “PU main display data” can be called in sequence by pressing the [SHIFT] key.

- 34 -

(5) Using the [MONITOR] key to select the monitor display

1) Press the [MONITOR] key, then the [HELP] key to call the monitor list.

2) Make selection with the arrow keys.

3) Press the READ key to display the monitor. Note that the monitors that may be read are limited.

1. Frequency

2. Current

3. Voltage

4. Alarm His

5. F Command

6. RPM

7. Shaft Trg

8. DC Link

9. Br Duty %

10. Therm OL

11. Peak I

12. DC Peak V

13. I/P Power

14. O/P Power

15. I/P Signal

16. O/P Signal

Input frequency [Hz] Input current [A] Input voltage [V] Eight items of error definitions are displayed.

SORRY No Function on This Numb. <CLEAR>

Converter output voltage [V]

SORRY No Function on This Numb. <CLEAR>

Input power [kW]

SORRY No Function on This Numb. <CLEAR>

Note: 1.Note that any value less than 5% of the high power factor

converter’s rated current cannot be detected or displayed.

2.By pressing th e [WRITE] key on any monitor display, the

first priority screen can be determined. This operation allows the first prior ity screen to be disp layed immediately after power-on or when the setting mode is switched to the monitoring mode.

To select automatic restart after instantaneous power failure

Pr.57 “restart selection”

• When automatic restart after instantaneous power failure has been selected i n the inver ter paramet er “re start coasti ng time ”, set

“0” in Pr. 57 “restart sel e c ti on ”.

• When “9999” is set in Pr. 57, the converter (FR-HC) will stop the

inverter output due to the alarm signal “E.IPF” even if automatic restar t after instantaneous p ower failure has been selected in th e inverter parameter.

Pr.57 Setting Restart Operation

0Yes

9999 (factory setting) No

CAUTION

The motor will star t s uddenly (after re set time has elap sed) when an instantaneous power failure has occurred. When the restar t after instanta neous power failure function is selected, stay away from the motor and machine. Apply the supplied CAUTION labels to easily identifiable positions when the restar t aft er instantane ous power failure function is selected.

- 35 -

To limit the error s reset f o r retry

E.OCT

Retry

Pr. 65 “retry selection”, Pr. 67 “number of retries at alarm

occurrence”, Pr. 68 “retry waiting time”, Pr. 69 “retry count display erasure”

• When an error occurs in th e high power factor converter, the retry function allows it to reset the alarm automatically and continue operation.

(1) With Pr. 65 “retry selecti on”, you can limit the high power factor

converter errors reset for retry.

Pr.65 Alarms Reset for Retry

0No retry 1 Overcurrent shut-off (OCT) 2 Power supply fault (IPF) (Note 4)

Overcurrent shut-off (OCT),

power supply fault (IPF)

(2) With Pr. 67 “number of retries at alar m occurren ce”, you can set

the number of retries to be made when a high power factor conve rter error occurs.

Pr.67 Setting Number of Retres Alarm Signal Output

0 (factory setting) Retry is not made. –

1 to 10 1 to 10 times Not output

101 to 110 1 to 10 times Output.

(3) With Pr. 68 “retry waiting time”, waitin g time from when a high

power factor converter error occurs until a restart is made can be set in the range 0.1 to 360s.

(4) By reading the value of Pr. 69 “retry count display”, the

cumulative number of restart times su ccessf ully made by retr y is provided. The set value of “0” erases thi s cumulative number of times.

Note: 1.The high power factor converter automatically starts

operation after the tim e set in Pr. 68 “retry waiting time” has elapsed. Exercise care not to jeopardize the operator.

2.The cumulative number in Pr. 69 “retry count display erasure” is incremented by “1” when retry operation is regarded as successful, i.e. when normal operation is continued without any alarm occurring during a period four times longer than the time set in Pr. 68 “retry waiting time”.

3.If alarms occur successively during a period four times longer than th e above waiting time set in Pr. 68, the scr een display of the parameter unit will be different from the display provided when the first retry is made. (Option fault “E.OPT”) Note that the error reset f or retry is not stored.

4.With 2 set in Pr. 65 “retr y selection” (power supply fault), the IPF signal is detected when a power supply fault occurs.

CAUTION

When you have selected the retry functi on, stay away from the motor and machine. They will start suddenly (after a given time has elapsed) when an ala rm occurs. When you have selected the retry function, apply the supplied CAUTION labels to easily identifiable positions.

- 36 -

To set parameter write disable

Write Inhibited

Pr.77 “parameter write disable selection”

• Prevents parameter values from being written from the parameter unit.

Pr.77 Setting Write Disable Function

1 Parameter write disable

2 (factory setting) Parameter write enable

Note: 1.Mo nitor-related parameters Pr. 51, Pr. 53, Pr. 55 and Pr.

56 may be set at any time.

2.The Pr. 77 value may be written at any time.

CAUTION

If the setting is changed during operation, the high power factor converter may stop operating due to al arm occurrence.

To change the language displayed on the parameter unit

Pr.145 “

parameter unit language switching

”

• You can select the language displayed on the four-language parameter unit FR-PU02ER

Set Value Language Displayed

0 English (factory setting) 1German 2 French 3 Spanish

Note: T his function is invalid for the FR-PU02

ARW

parameter (copy) unit is used.

-1

and copy unit FR-ARWER-1 (option).

-1

, FR-PU02E-1 or FR-

-1

- 37 -

T o make the output calibration of terminal FM

Meter

DC ammeter

1mA full-scale

Pr.900 “FM terminal calibration”

• The meter connected to ter minal FM can be calibrated from the parameter unit. This calibration function is common to all monitored data selected in Pr. 54 “FM terminal function selection”.

• Terminal FM provides the pulse output as shown below. The setting of Pr. 900 “FM terminal calibration” allows the meter connected to the converter to be calibrated from the parameter unit without providing a calibration resistor.

Calibration resistor (Note)

1mA

(+ )

( - )

Meter 1mA full scale Analog meter

Pulse width T1: Adjusted with Pr. 900

DC8V

Note: Calibration need not be made using Pr. 900 “FM term inal

calibration”. This r esistor is u sed when cali bration 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 co nnected. In this case, use both the resistor and Pr. 900 “FM terminal calibration” to make calibration.

• Monitoring using a digital meter A digital value can be displayed on a digital counter using the pulse train signal from the FM terminal. By making monitoring selection, the ratios of the FM terminal mon ito r ing ca n be set in Pr. 51 “input power monitoring reference”, Pr. 53 “input voltage monitoring reference”, Pr. 55 “bus voltage monitoring reference” and Pr. 56 “current monitoring reference”.

1440 pulses/s

- 38 -

Digital indicator

Digital meter Example: Koyo Electronic Industry's TC-41

FR-PU02E

Display

PARAMETER UNIT

-1

• Calibration procedure (1) Connect a meter across c onverter te rminals FM and SD. (Note

the polarity. FM is the positive terminal.)

(2) When a calibration resis tor has already been connected , adjust

the resistance value to zero or remove the resistor.

(3) Set the required value in Pr. 54 “FM terminal functio n selection”.

Preset the parameter value as required by the output signal.

1) Press the [SET] key. . . . . . The parameter setting

mode is entered.

SETTING MODE Set Pr. NO. FOR PR. List <HELP>

MONITOR

HELP

ACCEL DECEL THM

HIGH MID LOW

BOOST

SET

SHIFT

READ

EXT O P

CLEAR

V/FMINMAX

WRITE STOP

P U O P

FWD

REV

the [READ] key.

3) Input current is displayed.

4) Using the [ ] or [ ] key,

adjust the meter indicator

2) Type [9][0][0] and press

2) 5)

to a predetermined position

5) Press the [ WRITE] key. . . . . . Calibration is complete.

. . . . . The data as shown on

the right is displayed.

. . . . . The meter indica tor

moves. (It takes a long time until the indicator moves.)

900 FM Tune Run Inverter set 60.00Hz PU

901 AM Tune Mntrl 2.31A

<WRITE>PU

900 FM Tune Completed <MONITOR>

Press the [MO N ITOR] or [SET] key to switch to the corresponding mode.

- 39 -

2.3 HELP FUNCTIONS

Use the HELP key to select monitoring, set parameter values, or clear parameters. On any monitor sc reen, press the H ELP key twice to ca ll the help menu, w ith which variou s functions can be set or selected. Note that there are restrictions.

2.3.1 Definitions of the help function displays (1) Monitoring function

HELP key

Twice

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting

(2) PU operation function

HELP key

Read Read

1. Frequency

2. Current

3. Voltage

4. Alarm His

5. F Command

6. RPM

7. Shaft Trg

8. DC Link

9. Br Duty %

10. Therm OL

11. Peak I

12. DC Peak V

13. I/P Power

14. O/P Power

15. I/P Signal

16. O/P Signal

* This function cannot be used. Press the CLEAR key to return to the help selection

screen.

Input frequency [Hz] Input current [A] Input voltage [V] Alarm history display

SORRY No Function on This Numb. <CLEAR>

Converter output voltage [V]

SORRY No Function on This Numb. <CLEAR>

Input power [kW]

SORRY No Function on This Numb. <CLEAR>

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting

Read

1. PU; Diectly IN

2. JOG; Jogging

* This function cannot be used. Press the CLEAR key to return to the help

selection screen.

- 40 -

(3) Parameter setting function (Note that only “1 Setting” is valid)

HELP key

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting

Read

1. Setting MODE

Read

2. Pr. List

3. Set Pr. List

4. Def. Pr. List

* This function cannot be used. Press the CLEAR key to return to the help

selection screen.

SETTING MODE Set Pr. NO For Pr. List <HELP>

1 2 3 4

Set Pr. Lists Pr.0 Pr.1 Pr.2

DEF Pr. List Pr.0 Pr.1 Pr.2

Following the instruction on the screen.

(4) Parameter initialization function... Returns parameter values to the factory setting.

HELP key

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting

Read

1. Clear Pr.

2. Clear All

3. Clear None

(5) Alarm history display function

HELP key

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting

Read

1 5 2 6 3 7 4 8

Clear Pr. Exec <WRITE> Cancel <CLEAR>

Write

Clear Pr.

Executing

- 41 -

(6) Alarm history clear function (Erases alarm history)

return to the help selection screen.

HELP key

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting

Read

ALARM CLEAR Exec<WRITE>

Cancel<CLEAR>

Write

ALARM CLEAR

Completed

(7) Converter reset (Resets the high power factor converter)

Note: Though the disp lay shows inve rter reset, note that th e inverter is not res et. (To reset the inverter

together with the converter, terminals RSO-RES and terminals SE-SD must have been connected.)

HELP key

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting

Read

INV. RESET

Exec<WRITE> Cancel<CLEAR>

Write

FWD EXT

Note:

Returns to the screen at the power on (first priority screen (refer to page 35))

(8) Troubleshooting (Note that this function is invalid)

HELP key

1. MONITOR

2. PU Oper

3. Pr. List

4. Pr. Clear

5. Alarm Hist

6. Alarm Clear

7. Inv. Reset

8. T/Shooting * This function cannot be used. Press the HELP key to return to the previous screen or press the MONITOR or SET key

Read

1 M. Not Run 2 M. Spd Error 3 M. A/Dec Err

4 M. Curr. High

Note: 1.There are restrictions on the help functions of the high power factor conv erter compared to those

of the inverter.

2.When you have selected an invalid item, press the CLEAR key to return to the help selection screen.

- 42 -

2.4 CONVERTER RESET

The high power factor converter can be reset by any of the following three operations. Note that resetting clears (erases) the cumulative internal heat value of the electronic overcurrent protector and the number of retries.

Operation 1

Using the help function, reset the inverter. For details, see “7 CONVERTER RESET” on page 42.

Operation 2

Switch the power off once. After more than

0.1s, switch it on again.

Note: When the Pr. 57 (Coasting time for

Operation 3

Connect the reset terminal RES-SD for more than 0.1s, then disconnect.

Note: Avoid resetting the converter as part of its operation cycle.

automatic restart after instantaneous power failure/commercial power supplyinverter switch-over) setting is other than “9999”, this operation is mistaken for an automatic restart after instantaneous power failure and the inverter cannot be reset. Hence, the power should be switched on again about 5s after the control power has been lost.

- 43 -

3. PROTECTIVE FUNCTIONS

This chapter offers details on the “protective functions” of this product. Always read the precautions, etc. before starting use.

3.1 ERRORS.................................................................................................... 44

3.2 MAINTENANCE AND INSPECTION ......................................................... 46

3.1 E RRORS

If any fault has occurred with the high power factor converter, the corresponding protective function is activated to bring the high power factor converter to an alarm stop and automatically give the corresponding error (alarm) indication on the parameter unit display. When the protective function is activated, refer to page 42 on how to reset the converter.

3.1.1 Error (alarm) definitions and remedies

Parameter Unit Display

(Note 4)

Stedy Spd Oc

Inv. Overload

Stedy Spd Oc

Corrupt Memory

Retry No. Over

Inst. Pwr. Loss

CPU Fault CPU error

Under Voltage

Option Fault

Definition Cause Check Point Remedy

Overcurrent protection

Electronic overload protection

Main circuit device heat

Parameter error

Retry count excess

Instantaneous power failure protection

Power supply fault

Undervoltage protection

Option fault Displayed during error retry.

If the input current exceeds a given level during operation of the high power factor converter, the operations of the high power factor converter and inverter are stopped.

To protect the IPM, the electronic overload protection is activated in response to the high power factor converter input according to the inversetime characteristics to stop the operations of the high power factor converter and inverter.

If the main circuit devices are heated due to cooling fan stop, overload, etc., the high power factor converter is stopped.

If any stored parameter error occurs, the operations of the high power factor converter and inverter are stopped.

If proper operation cannot be resumed within the given number of retries, the outputs of the high power factor converter and inverter are stopped.

If power is restored within about 100ms after a power failure of longer than 15ms, the operations of the high power factor converter and inverter are stopped.

If cable disconnection or other power supply fault has occurred, the outputs of the high power factor converter and inverter are stopped.

If the CPU arithmetic does not end within a given period, the operations of the high power factor converter and inverter are stopped.

If the DC bus voltage falls below 150VAC (300VAC for 400V class), the operations of the high power factor converter and inverter are stopped.

Check for sudden load variation.

Check for overload on motor. Check for low carrier frequency on inverter side. (Note 3)

Check for overload.

Check if parameters are written too many times.

Find the fault cause.

Find the instantaneous power failure cause.

Check for power cable disconnection.

Check for a start of large-capacity motor.

Eliminate sudden variation. Change the fan, remove a fan obstacle. (Note 1)

Reduce load weight. Increase the high power factor converter capacity.

Reduce load weight. Change the fan.

Change the high power factor converter.

Check power supply system equipment, e.g. power capacity.

Note: 1.This alarm does not oc cur if the coo ling fan stops, but it will occur to prevent the main circuit devices

from overheating due to the cooling fan stopping.

2.If the alar m is still displayed on the parameter unit after reme dy, t he internal circuit may be faulty. Consult your sales representative.

3.For the E.THT error, the electronic overcurrent protection of th e inverter should ac tivate earlier than that of the high power factor converter. However, the inverter’s electronic overcurrent protection “E.THT” has the proper ty that it is activated earlie r at a higher carrier freq uency and later at a lower carrier frequency. Therefore, when the carrier frequency of the inverter is low, the electronic overcurrent protection of the high power factor converter may be activated earlier.

4.Displayed on the FR-PU02E

-1

(option) and is not displayed on the FR-PU03E (option).

- 44 -

3.1.2 Faults and check points

Fault Check Point

Checking the connections

• Check that wiring is correct.

Unit does not operate properly.

POWER lamp is not lit.

Charge lamp is not lit.

Reactors become unusually hot.

Inverter is inoperative.

Reactors generate unusual noise. Check that phase sequence is correct.

• Check that proper power supply voltage is applied.

• Check that phase sequence is correct.

When phase sequence is correct, check that terminals

SOF-SD or terminals RES-SD are connected.

Checking the connections

• Check that connections are correct.

• Check that control circuit terminals R, S, T are wired correctly.

• Check f or damaged resistor in the external box.

Checking the connections

• Check that connections are correct.

• Check that main circuit terminals R4, S4, T4 are wired correctly.

Checking the connections

• Check that the reactors 1 and 2 are connected in correct sequence.

Checking the settings

• Check that the parameter setting of the inverter is correct. (Since the parameter setting method varies with the inverter series, refer to the inverter instruction manual.)

- 45 -

3.2 MAINTENANCE AND INSPECTION

The high power factor converter is a static unit consis ting mainly of semiconductor devices. Daily inspection must be performed to pr event any fault from occurring due to adverse influence by the installati on environment, such as temperature, humidi ty, dust, dirt and vibration, changes in the parts with time, service life, and other factors.

3.2.1 Precautions for maintenance and inspection

For some shor t time af ter the power is switched off, the smoothi ng capac itor remai ns at a high voltage. Before accessing the high power factor converter for inspection, make sure that the charge lamp is off and check that the voltage across th e main circui t termin als P-N of the hig h power factor converter is 30VDC or less using a tester, etc. (F o r th e lo ca ti on of the cha rg e la mp, see the terminal block ar r a ng em en t on pa g e 60 .)

CAUTION

The reactors 1 and 2 are hot. Take care not to get burnt.

3.2.2 Check items (1) Daily inspection

• Check the following during operation: (1) Improper installation environment (2) Cooling system fault (3) Unusual vibration and noise (4) Unusual overheat and discoloration

• During operation, check the input voltage of the high power factor converter using a tester.

(2) Periodic maintenance and inspection

• Check the areas inaccessible during operation and requiring period inspection. (1) Cooling system: Clean the air filter, etc. (2) Screws and bolts: Check that they are securely tightened and retighten as necessary. (3) Conductors and insulating materials: Check for corrosion and damage. (4) Insulation resistance: Measure. (5) Cooling fan, smoothing capacitor, relay: Check and change if necessary.

Note:Have a proper understand ing of the definition s of power and error ( alar m) indic ations pr ovided for the

high power factor converter. Also, have a p roper un derstand ing of th e setti ngs with th e pa rameter unit and record proper set values. (Enter the values into the Customer Setting s ection of the “Parameter List” on page 31.)

See the next page for the Inspection List.

(3) Insulation resistance test using megger

(1) Before performing the insulation resistance test using a megger on the external circu it, disconnect

the cables from all terminals of t he hig h p ower factor convert er s o t hat the tes t voltage is not app li ed to the high power factor converter.

(2) For the continuity test of the control circuit, use a tester

(high resistance range) and do not use the megger or

Power supply

High power

factor converter

S4 T4

P N

Inverter

INV

buzzer.

(3) For the high power factor converter, conduct the

insulation resistance test on the main circuit only as shown on the right and do not perform the test

500VDC megger

Earth terminal

on the control circuit. (Use a 500VDC megger.)

- 46 -

Daily and Periodic Inspection

Area of Inspec-

tion

General

Main

circuit

Cooling

system

Display

Inspection

Item

Surrounding environment

Overall unit

Power

supply

voltage

General

Conductors,

cables

Ter mina l

block

Converter

module

Smoothing

capacitor

Relay

Resistor

Cooling fan

Display

Meter

Interval

Description

Check ambient tempe ratur e, humidity, dust, dirt, etc.

Check for unusual vibration and noise.

Check that main circuit voltage is normal.

(1) Check with megger

(across main circuit terminals and ground terminal).

(2) Check for loose screws

and bolts.

(3) Check for overheat on

each part.

(4) Clean. (1) Check conductors for

distortion.

(2) Check cable sheaths

for breakage.

(3) Check for discoloration. Check for damage. ! Visual check No fault

Check resistance across terminals.

(1) Check for liquid leakage. (2) Check for safety valve

projection and bulge.

(3) Measure electrostatic

capacity.

(1) Check for chatter during

operation.

(2) Check for rough surface

on contacts.

(1) Check for crack in

resistor insulation.

(2) Check for open cable.

(1) Check for unusual

vibration and noise.

(2) Check for loose

connection.

(1) Check for power lamp

blown.

(2) Clean. Check that reading is

normal.

Periodic

Daily

year2years

! (1) Disconnect all cables

! ! (1), (2) Visual check. (1), (2) No fault.

! !

Method Criterion Instrument

See note on page 13.

Visual and auditory checks.

Measure voltage across high power factor converter terminals R, S, T-P 4, S 4, T4.

from high power factor converter and measure across terminals R4, S4, T4, P, N and ground terminal with

megger. (2) Retighten. (3) Visual check.

Disconnect cables from converter and measure

across terminals R4, S4, T4 P, N with tester ×1 range.

(1), (2) Visual check. (3) Measure with capac-

ity meter.

(1) Auditory check. (2) Visual check.

(1) Visual check. Cement

resistor, wirewound

resistor. (2) Disconnect one end

and measure with

tester. (1) Turn by hand with

power off. (2) Retighten.

(1) Lamps indica te

indicator lamps on

panel. (2) Clean with rag.

Check reading of meters on panel.

Ambient temperature:

-10°C to +50°C, nonfreezing. Ambient humidity: 90% or less, non-condensing.

No fault. 170 to 242V

(323 to 506V) 50Hz　 170 to 253V (323 to 506V) 60Hz

(1) 5M or more. (2), (3) No fault.

(See the next page.) Analog tester

Ω

(1), (2) (3)85% or more of

rated capacity.

(1) No fault. (2) No fault.

(1) No fault. (2) Error should be

within ±10% of indicated resistance value.

(1) Smooth rotation. (2) No fault.

(1) Check that lamps

are lit.

Must satisfy specified and management

Ω

No fault.

values.

Thermometer, hygrometer,　

recorder

Tester, digital multimeter

500VDC class megger

Capacity　 meter

Tester, digital multimeter

Voltmeter, ammeter, etc.

Customer

setting

Note:Values f or the 400V class are indicated in parentheses.

- 47 -

• Checking the converter module

(1) Disconnect the external power supply cables (R4, S4, T4, N, P). (2) Prepare a tester. (Use 1 range.)

Ω

Change the polarity of the tester alternately at the main circuit terminals R4, S4, T4, P and N of the converter, and check for continuity.

Note: 1.Before measurement, check that the smoothing capacitor is discharged.

2.At the time of discontinuity, the measured value indicated is a nearly infinite value. Due to the influence of the smoothing capacitor, continuity may be instantaneously established a nd i nfi nite not indicated. At the ti me of continuity, t he measured value is several to several ten ohms dependi ng on the module type, tester type, etc. If all meas ured values are almost t he same, the modu les are without fault.

Converter module

Tester Polarity

R4 P Discontinuity

P R4 Continuity

S4 P Discontinuity

P S4 Continuity

T4 P Discontinuity

P T4 Continuity

R4 N Continuity

N R4 Discontinuity

S4 N Continuity

N S4 Discontinuity

T4 N Continuity

N T4 Discontinuity

Measured

Value

(Assumes the use of an analog meter.)

R4 S4 T4

D1 D2 D3

- 48 -

3.2.3 Replacement of parts

The high power factor converter consists of many electronic parts such as semiconductor devices. The following parts may deteriorate with age because of their structures or physical charact eristics, leading to reduced perfor mance or failure of the high power factor converter. For preventive maintenance, the par ts must be changed periodically. See the following table for the high power factor conver ter par ts r eplacement gui de. Lamps and other shor tlife parts must also be changed during periodic inspection.

Replacement Parts of the High Power Factor Converter

Part Name

Cooling fan 2 to 3 years Change (as required)

Smoothing capacitor in

main circuit

Smoothing capacitor on

control board

Relays – Change as required.

Standard Replacement

Interval

5 years Change (as required)

5 years Change the board (as required).

Description

Note:For part replacement, contact the nearest Mitsubishi FA center.

(1) Cooling fan

The cooling fan cools heat-generating parts su ch as the main circuit semi conductor devices. The life of the cooling fan bearing is usually 10, 000 to 35,000 hours. Hence, the cooling fan must be changed every 2 to 3 years if the high power factor converter is run continuously. When unusual noise and/or vibration is noticed during inspection, the coo li ng fan must be changed immediately.

(2) Smoothing capacitors

A large-capacity al uminum el ectroly tic capa citor is used for smoothi ng the DC in the main circui t, and an aluminum electrolyti c capacitor is also u sed for stabilizing the contr ol power in the control ci rcuit. Their characteristics are adversely affected by ripple current, etc. When the high power factor converter is operated in ordinary, air-conditioned environment, change the capacitors about every 5 years. When 5 years have elapsed, the capacitors will deteriorate more rapidly. Check the capacitors at leas t every year (less than six months if the life will be expired soon). Check the following:

1) Case (side faces and bottom face for ex pansion)

2) Sealing plate (for remarkable warp and extreme crack)

3) Explosion-proof valve (for excessive val ve expansion and operation)

4) Appearance, external crack, discoloration, leakage. When the measured capacitance of the capacitor has reduced below 85% of the rating, change the capacitor. For capacitance measurement, it is recommended to use a handy device available on the market.

(3) Relays

To prevent a contact fault, etc., relays must be changed according to the number of accumulative switching times (switching life).

- 49 -

3.2.4 Measurement of main circuit voltages, currents and powers

• Measurement of voltages and currents When instruments for commercial frequency are used for measurement, measure the following circuits using the following instruments.

• When installing instruments, etc. on the high power factor converter output side When the wiring distance is long between the high power factor converter and inverter, the instruments may generate heat due to line leakage currents in especially 400V class. Select the devices which have large enough current rating.

• There is an output voltage across te rmi nals P-N of th e high power factor converter and thi s voltage can be measured by a moving-coil instrument (tester). This voltage varies with the power supply voltage and reduces when load is applied.

Power supply

External box

Reactor 1

Reactor 2

Converter

To inverte

External box Converter

Reactor 1

Power supply

Power meter

Recommended: YOKOGAWA251 Digital power meter (Can measure voltage, current, power and power factor)

Reactor 2

To inverter

• Classification and Application of Indicating Electric Instruments by Operation Principle

Type Symbol Principle Indication

Uses force working between the

Moving-coil type

magnetic field of a permanent magnet and a current flowing in the moving coil.

Uses force working between the

Moving-iron type

magnetic field of a current flowing in the fixed coil and the moving iron.

Electrodynamic type

Air core

Uses force working between currents flowing in two coils.

(Mean value)

(Effective value)

AC/DC

(Effective value)

Applied

Instrument

Voltmeter, ammeter, resistance meter, thermometer, flux meter, speed meter

Voltmeter, ammeter

Wattmeter, voltmeter, ammeter

High in sensitivity and most often used. Power consumption small, rarely affected by external magnetic field.

Rigid in structure and low in price. Greatly affected by external magnetic field, frequency and waveform.

Wattmeter is graduated equally. Affected by external magnetic field and consumes large power. May be used as a standard AC/DC instrument.

Features

- 50 -

Measuring Points and Instruments

Item Measuring Point Measuring Instrument

Power supply voltage

Power supply side current

Power supply side power

Power supply side power f act or

Pf1

Converter output Across P-N

Meter signal Across FM(+)-SD

Alarm signal

(Reference Measured Value)*

Remarks

Across R-S, S-T and T-R

R, S and T line currents At R, S and T, and across R-

S, S-T and T-R

Moving-iron type AC

voltmeter

Moving-iron type AC

ammeter

Electrodynamic type

single-phase wattmeter

Commercial power supply 170 to 242V (342 to 506V) 50Hz 170 to 253V (342 to 506V) 60Hz

=W11+W12+W13

P (3-wattmeter method)

Calculate after measuring power supply voltage, power supply side current and power supply side power.

= × 100%

-----------------

3V1I

Inverter LED display is lit.

Moving-coil type

(such as tester)

1.35 × V1 Max. 380V (760V) during regenerative operation

Approx. 5VDC at max. frequency (without meter)

Moving-coil type

(T ester, etc. may be used)

(Internal resistance:

50kΩ or larger)

Pulse width T1: Adjusted with Pr. 900

Approx. 10VDC at maximum frequency (without frequency meter)

20 to 30VDC when open. ON voltage: 1V or less

Continuity check

<Normal> <Fault> Across A-C Across B-C

Moving-coil type

(such as tester)

Across A-C:

Discontinuity Continuity

Across B-C:

Continuity Discontinuity

SD is common.

Note 1: Do not use a tester because accurate data will not be obtained. * Values in parentheses indicate those for 400V class.

- 51 -

4. PRECAUTIONS FOR SELECTION

This chapter provides details on “precautions for selection” in using this product. Always read the precautions, etc. before starting use.

4.1 PRECAUTIONS FOR SELECTING PERIPHERAL DEVICES .................. 52

4.1 PRECAUTIONS FOR SELECTING PERIPHERAL DEVICES

4.1.1 Measures against noises

In this section, noises indicate those of more than 40th to 50th high frequencies in a power distribution system, which assume generally irregular conditions. Some noises enter the high power factor converter to adversely affect it and others ar e radiated by the high power factor converter to adversely affect peripheral devices. Though the high power factor converter is designed to be im mune to noise s, it handles low-level signals, so it re quires the following bas ic measures to be taken. Also, since the high p ower factor converter chops ou tput voltage at hi gh carr ier frequency, it could generate noises. If these noise s affect peripheral devices, measures should be taken to suppress noises. The measures differ slightly depending on noise propagation paths.

1) Basic measures

• Do not run the power cables (I/O cables) and signal cables of the high power factor converter 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 screen of the shield cables to terminal SD.

• Ground the reactors 1, 2, external box, high power factor converter, inverter, motor, etc. at one point.

2) Measures against noises which enter and affect the high power factor converter

When devices which generate many noises (which use magnetic contactors, magnetic brakes, many relays, for example) are installed near the high power factor converter and the high power factor converter may be affected by noises, the following measures must be taken:

• Provide surge suppressors for devices that generate many noises to suppress noises.

• Fit data line filters to signal cables.

• Ground the shields of the detector connection and control signal cables with a metal cable clamp.

3) Measures against noises which are radiated by the high power factor converter to affect peripheral devices

Noises generated by the high power factor converter are largely classified into those radiated by the cables connected to the high power factor converter and high power factor converter’s main circuit (I/O), those electromagnetically and electrostatically inducted to the signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power supply cables.

Converter-generated noises

Air-propagated noises

Magnetic induction noises

Static induction noises

Cable-propagated noises

.. Path 4, 5

.. Path 6

Noises directly radiated by converter

Noises radiated by power cables

Noises propagated through power cables

Sneak noises from ground cable due to leakage current

.. Path 1

.. Path 2

.. Path 7

.. Path 8

- 52 -

Telephone

Reactor 1

Extern al box

Reactor 2

High power

factor

converter

Inverter

Instrument

Receiver

Motor

Noise Path Measures

When devices which handle low-level signals and are susceptible to noises (such as instruments, receivers and sensors) are installed near the high power factor converter and their signal cables are contained in the same panel as the high power factor converter or are ru n near the high power factor converter, the devices may be affected by air-propagated noises and the following measures must be taken: (1) Install easily affected devices as far away from the high power factor converter and inverter as possible.

1, 2, 3

(2) Run easily affected signal cables as far away from the high power factor converter and inverter as

possible.

(3) Do not run the signal cables and power cables (high power factor converter I/O cables) in parallel with

each other and do not bundle them. (4) Insert line noise filters into I/O and radio noise filters into cables input to suppress cable-radiated noises. (5) Use shield cables for signal cables and power cables and run them in individual metal conduits to

produce further effects. When the signal cables are run in parallel with or bundled with the power cables, magnetic and static

induction noises may be propagated to the signal cables to affect the devices and the following measures must be taken: (1) Install easily affected devices as far away from the high power factor converter and inverter as possible.

4, 5, 6

(2) Run easily affected signal cables as far away from the high power factor converter and inverter as

possible. (3) Do not run the signal cables and power cables (high power factor converter and inverter I/O cables) in

parallel with each other and do not bundle them. (4) Use shield cables for signal cables and power cables and run them in individual metal conduits to

produce further effects. When the power supplies of the peripheral devices are connected to the power supply of the high power factor

converter in the same line, high power factor converter-generated noises may flow back through the power

supply cables to the devices and the following measures must be taken: (1) Install the radio noise filter (FR-BIF) to the power cables (Input cables) of the high power factor converter. (2) Install the line noise filter (FR-BLF) to the power cables (I/O cables) of the high power factor converter.

When a closed loop circuit is formed by connecting the peripheral device wiring to the high power factor

converter, leakage current may flow through the ground cable of the high power factor converter to affect the device. In such a case, disconnection of the ground cable of the device may cause the device to operate properly.

Sensor power supply

Sensor

- 53 -

4) Using options to suppress noises

To suppress noises radiated by cables, the radio noise filter (FR-BIF) and line noise filter (FR-BLF) are available. (Refer to page 68.) For more information, refer to the corresponding manual.

• Example (FR-A500)

Power supply

NFB MC

Line noise filter (FR-BLF)

Radio noise filter (FR-BIF)

Reactor 1

(FR-HCL01)

FRBIF

FRBLF

R S

S2 T2

External box

(FR-HCB)

R2 S2 T2

Filter capacitor

Resistor

MC1 MC2

R3 S3 T3

Reactor 2

(FR-HCL02)

High power factor

converter(FR-HC)

MC1 MC2

R4 S4 T4

RDY RSO

Y1 or Y2

R S T R1 S1

Line noise filter (FR-BLF)

Inverter (FR-A500 series) R S T

X10 RES X11 SD

R1 S1

FR-

V W

BLF

Motor

Keep terminals R1, S1 of the high power factor converter unconnected.

Inserting a filter in front of terminal R, S, T of the high power factor converter

will produce more effective noise reduction. Refer to the noise filter manual for installation procedure of the noise filter.

- 54 -

4.1.2 Peripheral device list

Voltage

200V class

400V class

High Powe r Factor

Converter T ype

FR-HC-7.5K 50AF 50A S-N35

FR-HC-15K 100AF 75A S -N65 FR-HC-30K 225AF 125A S-N125 FR-HC-55K 225AF 225A S-N220

FR-HC-H7.5K 30AF 30A S-N20

FR-HC-H15K 50AF 50A S-N25 FR-HC-H30K 100AF 75A S-N65 FR-HC-H55K 225AF 125A S-N125

No-fuse breaker (NFB note 1)

or leakage breaker (NV) (note 2)

Magnetic

Contactor (MC)

Note: 1.Select the NFB according to the capa city of the high power factor converter and install on e NFB

per high power factor converter.

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 primary side of the high power factor converter tripped, check for wiring fault (e.g.short circuit), damage to internal parts of the inverter (high power factor converter), etc. Identify the cause of the breaker trip, then power on the breaker after removing the cause of the trip.

4.1.3 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:

• Breaker for harmonic and surge Rated sensitivity current: I n 10×(lg1+lg2+lg3+lgm)

∆

• Standard breaker Rated sensitivity current:

In10×{lg1+lgn+lg2+3×(lg3+lgm)}

∆

where, lg1, lg2, lg3:leakage currents of cable path

during commercial power supply operation

lgn* :leakage current of noise filter on converter

input side

lgm :leakage current of motor during commercial

power supply operation

5.5mm

×5m 5.5mm2×50m 5.5mm2×70m

Noise

filter

High power factor

converter

lg1 lgn lg2 lg3

Inverter

200V 2.2kW

lgm

Note: 1.Install the NV on the primar y (power supply) side

of the power return common converter.

2.Ground fault on the o utput side of t he inverter can be detected at the running frequency of 120Hz or lower.

3.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 class C grounding (10 Ω or less).

4.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 thi s case, do not ins tall the breaker since the eddy current and hysteresis loss increase and the temperature rises.

5.The follo wing models are standard breaker s Type BVC1, BC-V, NVB, NV-L, NV-G2N, NV-G3NA, NV-2F type leakage current relay (except for NV-ZHA), NV

Example of leakage curr ent 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

Leakage current

(mA)

23.5

814223880150

5.5

Cable size (mm2)

30 60 100

Leakage Current Example of 3-Phase Induction Motor during Commercial Power Supply Operation (200V 60Hz)

2.0

1.0

0.7

0.5

0.3

Leakage current

0.2

(mA)

0.1

Selection Example (for the diagram shown on the left) (mA)

Breaker for

harmonic and su rge

Leakage current lg1

(mA)

Leakage current lgn

(mA)

Leakage current lg2

(mA)

Leakage current lg3

(mA)

Motor leakage

current lgm (mA)

Total leakage current

(mA)

Rated sensitivity cur-

rent ( lg×10) (mA)

----------------- -

33× =0.17

1000m

0 (without noise filter)

----------------- -

33× =1.65

1000m

----------------- -

33× =2.31

1000m

4.31 7.97

30 100

1.5

3.7

7.5 15223755

2.2

5.5

1118.5 30 45

Motor capacity (kW)

Standard

Breaker

50m

70m

0.18

with AA neutral wire open-phase protection The following models are f or harmonic surge NV -C/NV-S/MN series, NV30-F A, NV50-FA, BV-C2, leakage current alarm breaker (NF-Z), NV-ZHA, NV-H

* Note the leakage current value of the noise filter installed on the high power factor converter input side.

(For Mitsubishi’s dedicated filters, see page 71.)

- 55 -

5. SPECIFICATIONS

This chapter offers details on the “specifications” of this product. Always read the precautions, etc. before starting use.

5.1 SPECIFICATIONS...................................................................................... 56

5.2 OPTIONS ................................................................................................... 68

5.1 SPECIFICATIONS

5.1.1 Standard specifications

Input Voltage 200V Class 400V Class

Type FR-HC- 7.5K 15K 30K 55K H7.5K H15K H30K H55K Applicable inverter

capacity (W) Rated input voltage (V) Rated input current (A) 33 61 115 215 17 31 57 110

Overload current rating 150% for 1 minute Permissible power supply

voltage fluctuation Permissible power supply

frequency fluctuation Input power factor 0.99 or more (for load factor of 100%)

Protective structure Cooling system Forced air cooling

Approx. weight

Input signal Reset, converter stop, monitor switching

Output signal

Control system High carrier frequency sine-wave PWM control Display Protective function Power supply fault, overcurrent, device fault, undervoltage, transistor thermal relay (inverter protection)

Environment

Altitude 1000m or less below sea level Vibration

Unit (kg) 8 15 29 70 9 16 35 72

Accessory (kg)* 20.3 30.8 66.6 96.3 22.7 31.9 51.3 93.3

Parameter

unit

Ambient

temperature

Ambient humidity

Ambience Indoors. (No corrosive gases, flammable gases, oil mist, dust and dirt)

7.5K 15K 30K 55K 7.5K 15K 30K 55K Three-phase 200V to 220V 50Hz

/200V to 230V 60Hz

170 to 242V 50Hz, 170 to 253V 60Hz 323 to 506V 50/60Hz

±5%

Enclosed type IP20

Inverter run enable signal, converter operating, overload alarm, meter, alarm signal, reset,

multi-purpose (two signals selected from among power supply phase detection signal, voltage match,

instantaneous power failure detection, and driving/regenerative mode judgment) output

• Power supply frequency , input current, power supply voltage, input power, converter output voltage

• Eight alarm definitions are stored.

Open type IP00

-10°C to +50°C (non-freezing)

90%RH or less (non-condensing)

5.9m/s

Three-phase 380V to 460V 50/60Hz

Enclosed type IP20

or less

Open type IP00

Note: 1.Select the model carefully.

When using inve rt ers wi th the h igh pow er fac tor conv er te r, the sum of all in ver ter ca pacit ies s hou ld be within the applicable capacity:

Example: Inverter capacities applicable to FR-HC-15K FR-A520-15K

FR-A520-11K+FR-A520-3.5K

2.The 400V class high power factor converters are provided with H in their type codes.

3.The overload current rati ng % value indicates the ratio of the overlo ad current to the converter ’s rated input current. F or repeated use, it is necessary to wait until the high power fac tor converter and inverter return to less than the temperature under 100% load.

4.Storage temperature is applicable during a short period, e.g. in transit.

5.When the 400V class converter is used and the power supply voltage fluctuation is outside the range 342V to 484V, the internal transformer setting must be changed. (Refer to page 24.)

- 56 -

5.1.2 Block diagram

R1S1

FR-HCL01

R S

Power supply

FR-HCB(Exlternal box) FR-HC (High power factor converter)

R2 S2 T2

Filter C

MC1

R3 S3

FR-HCL02

R3 S3 T3

R4 S4 T4

MC1

Current

detection

Overcurrent

detection

CHARGE

Inverter

FR series

R1 S1

R1 S1 (Note 2)

Motor

MC2

Ground

(Note 1)

MC2

RES

SOF

POWER

Control

power supply

CON

FR-PU02E

Phase detection

CPU

-1

ALARM

C FM

Calibration resistor (Note 3)

RDY

CVO

RSO

Meter

Open

collector

output

Note: 1.Keep terminals R1, S1 of the high power factor converter unconnected.

2.Except the FR-E500 and A024 series.

3.The parameter unit need not be used for calibration. This resistor is used for calibration of a remotely located frequency meter. Note that the needle of the frequency meter may not deflec t to fullscale when the calibration resistor is connected. In this case, use both the resistor and parameter unit to make calibration.

4.The R, S, T terminals of the high power factor converter (FR-HC) must be connected to the power supply. Running the inverter without connecting the terminals to the power supply will damage the high power factor converter (FR-HC).

- 57 -

5.1.3 Terminals

Type

Main

circuit

Control ciruit

Terminal

Symbol

R, S, T Power input

R4, S4, T4 Power input Connect to reactor 2.

P, N Inverter connection Connect to P and N terminals of inverter.

MC1,CMC2 MC connection Connect to MC1, MC2 in external box.

Terminal Name Description

Ter minals for power supply ph ase, power voltage detection and control power input. Co nnect to commercial power supply. Running the inverter without connecting these terminals will damage the high power factor converter (FR-HC).

Function Circuit Remarks

RES Reset

SDF Converter stop C onverter gate shut-off

Input signals

SD Common terminal

RDY Inverter run enable signal

CVO Converter operating Output during IGBT switching

OL Overload alarm

Output signals

Monitoring switch-over

Multi-Purpose output

terminal

Converter operation stop (used to return from error)

Selection of FM output and PU monitor display

Common terminal (input, FM)

Closed only when alarm occurs or reset (RES) signal is input.

Overcurrent (150% load or more) Overvoltage (output at overvoltage trip-less operation)

Multi-purpose output External fault

24VDC

sink circuit

–

Open

collector

Operations of converter and all inverters connected are stopped.

RDY signal is open. Inrush MC is closed.

• Input current monitor

• Bus voltage monitor

• Input voltage monitor

• Input power monitor

Inverter is stopped.

RDY signal open: Inverter operative RDY signal closed: Inverter inoperative

• Power supply phase detection signal

• Output voltage match signal detection

• Instantaneous power failure detection

• Driving/regenerative mode judgment

RSO Converter reset

FM Meter connection terminal

SD Contact input common Common terminal (I/O, FM)

A, B, C Alarm conntact Alarm output

Open collector output

common

Output when converter is reset.

Pulse train signal is output in proportion to input current.

Open collector common

PWM pulse

output

– –

Change-over

contact

Inverter is reset.

Depends on setting of X1, X2 terminals.

- 58 -

Terminal Block for Control Circuit

A B

Common to all models Structure:2-stage molded terminals Screw size: M3

C (NC) (NC) (NC) (NC) (NC) (NC) (NC)

Y2 Y1

OL RSO CVO RDY

X1 SOF RES

(NC) (NC) (NC) (NC) (NC) (NC) (NC)

Note: Terminals (NC) are free terminals. Keep them open.

Actually, no terminals symbols are printed on these terminals.

- 59 -

5.1.4 Terminal block arrangement

(1) 200V class (2) 400V class

FR-HC-7.5K FR-HC-H7.5K

Control circuit terminal block

R1S1

RSTR4S4T4

Screw size

Charge lamp (yellow)

MC1 MC2

FR-HC-15K

Screw size

Control circuit terminal block

Screw size M6

RSTR4S4T4N P

(M6)

Screw size M3.5

MC2

MC1 (NC)

•Terminals MC1, MC2 are located under the terminal symbol cover. Connect terminals MC1, MC2 after removing the terminal symbol cover.

R1 S1

(NC)

Charge lamp (yellow)

Control circuit terminal block

R1S1

RSTR4S4T4

Screw size

Charge lamp (yellow)

MC1 MC2

FR-HC-H15K

Screw size

Control circuit terminal block

Screw size M6

RSTR4S4T4N P

(M6)

Screw size M3.5

MC2

MC1 (NC)

•Terminals MC1, MC2 are located under the terminal symbol cover. Connect terminals MC1, MC2 after removing the terminal symbol cover .

R1 S1

(NC)

Charge lamp (yellow)

FR-HC-30K FR-HC-H30K

Screw size

Control circuit terminal block

RST R4S4T4 N P

Screw size M4 Screw size M3.5 Screw size M8

(M6)

R1 S1

MC2 (NC)MC1 (NC)

Charge lamp (yellow)

RST R4S4T4 N P

Screw size M5 Screw size M3.5 Screw size M6

(M6)

FR-HC-55K FR-HC-H55K

Screw size

Control circuit terminal block

RST R4S4T4N P

Screw size M4

(M6)

Screw size M3.5 Screw size M12

R1 S1

MC2 (NC)MC1 (NC)

Charge lamp (yellow)

RST R4S4T4 N P

Screw size M5 Screw size M3.5 Screw size M8

(M6)

Control circuit terminal block

Screw size

MC2 (NC)MC1 (NC)

Screw size

MC2 (NC)MC1 (NC)

R1 S1

R1S1

Charge lamp (yellow)

Note: Keep the control circuit terminals R1, S1 of the high power factor converter unconnected. Note: Ter minals (NC) are fr ee terminals. Keep them open. Actually, no terminal symbols are printed on thes e

terminals.

- 60 -

5.1.5 Outline drawings (400V class models have H in their type codes) (1) High power factor converter (FR-HC)

• FR-HC-7.5K, H7.5K

2-φ6 hole

* Parameter

unit installation position

(Unit: mm)

Protecti ve bush

• FR-HC-15K, H15K

* Parameter

unit installation position

195 220

230 250

300

285

210

View arrow

7.5

2-φ10 hole

380

400

190

2.3

242

View arrow

(Unit: mm)

• FR-HC-30K, 55K, H30K, H55K

* Parameter

unit installation position

2-φC hole

(Unit: mm)

View arrow

Inverter Type

FR-HC-30K, H30K 340 324 270 550 530 510 10 195 78 10 FR-HC-55K, H55K 480 464 410 700 675 645 15 250 130 12

3.2

W W1 W2 H H1 H2 H3 D D1 C

- 61 -

(2) Reactor 1 (FR-HCL01), reactor 2 (FR-HCL02)

Make sure that the reactors 1 and 2 have the same capacity as the high power factor converter.

1) Reactor 1 (FR-HCL01)

• FR-HCL01-7.5K to 30K, H7.5K to H55K

4-φd

• FR-HCL01-55K

R2 S2 T2

Terminal M12

4-φd

190

(Unit:mm)

Approx.

Type H W W1 D D1 d

weight

(kg)

2 FR-HCL01-7.5K 155 160 145 100 58 5 3.3 0 FR-HCL01-15K 205 190 170 130 73 6 6.0 0 FR-HCL01-30K 230 220 200 170 88 6 10.8 V FR-HCL01-55K 260 210 165 225 160 8 21.0 4 FR-HCL01-H7.5K 150 160 145 100 65 5 4.2 0 FR-HCL01-H15K 195 190 170 130 80 6 7.2 0 FR-HCL01-H30K 215 220 200 140 90 6 12.0 V FR-HCL01-H55K 255 280 255 190 112 8 22.5

2) Reactor 2 (FR-HCL02)

• FR-HCL02-7.5K to 30K, H7.5K to H55K

4-φd

• FR-HCL02-55K

With terminal block cover

M12

4-φd

Type HH1WW1DD1d

2 F R-HCL02-7.5K 230 0 FR-HCL02-15K 270 0 FR-HCL02-30K 320

V FR-HCL02-55K 470 240 430 270 360 240 10 63.0

4 FR-HCL02-H7.5K 220 0 FR-HCL02-H15K 260 0 FR-HCL02-H30K 310

V FR-HCL02-H55K 380

240 210 160 110 7 12.8

–

260 230 170 120 7 20.5

–

340 310 180 130 10 37.0

–

240 210 160 110 7 13.8

–

260 230 170 120 7 20.5

–

340 310 180 130 10 35.0

–

400 270 285 240 10 60.0

–

D1 280

(Unit:mm)

Approx.

weight

(kg)

- 62 -

3) Identification of the reactor 1 (FR-HCL01) and reactor 2 (FR-HCL02)

Each reactor has a rating plate. Connect the reactors 1 and 2 carefully. If they are connected in a wrong sequence, they will be hot and it will be hazardous.

Rating plate

Reactor 1 (FR-HCL01) Reactor 2 (FR-HCL02)

AC REACTOR TYPE FR-HCL01 BKO-CA SERIAL

Note: Check this “TYPE” to discriminate between reactors 1 an d 2.

(Note)

AC REACTOR TYPE FR-HCL02 BKO-CA SERIAL

- 63 -

(3) External box (FR-HCB)

Type H H1 W W1 D

FR-HCB-7.5K

FR-HCB-15K 4.7

0 0

FR-HCB-30K

FR-HCB-55K 12.6 FR-HCB-H7.5K

FR-HCB-H15K 4.7

0 0

FR-HCB-H30K 4.8

FR-HCB-H55K 450 435 270 200 203 9.9

320 305 190 130 165

450 435 270 200 203

320 305 190 130 165

1) Outline

Wiring hole

2-pear-shaped hole M6

(Unit: mm)

Approx.

weight

(kg)

4.7

9.7

5.7

Pear-shaped

Rating

plate

2.3

hole details

- 64 -

2) Terminal bloc k (a) FR-HCB-7.5K/15K/H7.5K/H15K/H30K

TB1

T2R2

(b) FR-HCB-30K/55K/H55K

TB1

T2R2

TB2

MC1 (NC) MC2

GND

TB2

MC1 (NC) MC2

Type TB1 TB2 GND

FR-HCB-7.5K/H7.5K FR-HCB-15K/H15K/H30K

Type TB1 TB2 GND

FR-HCB-30K M6 M3. 5 M6 FR-HCB-55K/H55K M8 M3.5 M6

M5 M3.5 M5

GND

Note: Terminals (NC) are free terminals. Keep them open. Actually, no terminal symbols are printed on these

terminals.

- 65 -

5.1.6 Panel cutting dimension diagrams (For use of the heat sink outside mounting attachment)

(

)

(

)

•FR-HC-7.5K/H7.5K •FR-HC-15K/H15K

High power factor converter outline

300

9.5

4-M5 screw

195 212

High power fact or

320

305

•FR-HC-30K, 55K/H30K, H55K

converter outline

Unit: mm

High power fact or

converter outline

N-C screw

6-M8 screw

200

102

244

400

19.5

230 260

335

440

12.5

(Unit: mm)

W3 W1

Unit: mm

Inverter T ype W 1 W2 W3 H1 H2 H3 H4 H5 H6 H7 H8 N C FR-HC-30K, H30K 330 265 290 516 12 95 540 85 – 510 15 6 M8 FR-HC-55K, H55K 470 390 430 650 15 70 ––730 645 24.5 4 M10

- 66 -

5.1.7 Parameter unit (FR-PU02-1/FR-PU02E-1/FR-PU02ER-1) dimension diagram

12 7

127

117

Note: The length of the installation screw should be selected so that it

does not exceed the effective installation screw depth of the parameter unit.

FR-PU02E-1 Specifications

Item Specifications

Ambient

temperature

Ambient humidity 90%RH Non-condensing

Operating ambience No oil mist and corrosive gases. Minimal dust and dirt.

Power supply Power is supplied from the inverter.

Connection Loaded to the inverter directly or connected by the cable.

Display LCD (liquid crystal display , 13 characters × 4 lines)

Keyboard 24 keys (covered with polyurethane film)

Size 127 (H) × 70 (W) × 12 (D)

Operating -10 to +50°C (Note 1) Note: 1. When the temperature is Storage -20 to +65°

2-M3 screw Effective depth 4.5

(Unit: mm)

less than about 0°C, the liquid crystal display (LCD) may be slower in operation. And high temperature may reduce the LCD life.

2. Do not expose the liquid crystal display directly to the sun.

Panel cutting dimensions for installation of the parameter unit to a panel or the like

• Parameter unit cable (straight type) is used and is not fixed to the panel

Panel cut portion

(38.5)

820

2-φ4 hole

117

(View as seen from the parameter unit)

• Parameter unit cable (L type) is used and fixed to the panel

Panel cut portion

4 hole

2-φ3.5 hole

6 countersunk

10.5

38.5

208

1315

2-φ4 hole

117

(Unit: mm)

- 67 -

5.2 OPTIONS

By using the following options, the functions of the high power factor converter can be increased. Make a correct selection. The following options are all external dedicated option units.

5.2.1 Option list

Name Type Application, Specifications, Etc.

Parameter unit (Japanese) FR-PU02 Parameter unit (English) FR-PU02E Parameter unit (4 languages) FR-PU02ER Parameter copy unit (Japanese) FR-ARW

Parameter copy unit (English) FR-ARWE Parameter copy unit (4 languages) FR-ARWER Accessory cover

Parameter unit cable

Heat sink outside mounting attachment

Dirt-protection structure attachm ent

Conduit connection attachment Radio noise filter FR-BIF-(H)* For radio noise reduction

Line noise filter FR-BLF For line noise reduction

FR-CBL

FR-ACN

FR-ACV

FR-AFN

-1

Interactive parameter unit using LCD display The LCD display and ten-key pad of the FR-PU02

English. For use in English, German, French and Spanish.

-1

Allows parameter settings to be read in batch and copied to the other converter.

The LCD display and ten-key pad of the FR-ARW-1 are indicated in English.

For use in English, German, French and Spanish.

-1

Blind cover fitted after the parameter unit is removed from the converter.

Cable for connection of the parameter unit or parameter copy unit. Straight or L types are available.

Used to place only the heat generating section of the high power factor converter in the back of the control box.

By installing this option, the high power factor converter meets the totally enclosed structure specifications (IP40).

Used to connect a conduit pipe directly to the high power factor converter. (IP20)

are indicated in

-1

* 400V class models have H in their type codes. Note: Not all options are available in all countries, please refer to your Mitsubishi distributor.

- 68 -

5.2.2 External dedicated options

(E)

Name (Type) Specifications, Structu re, Etc. Remarks

Parameter copy unit FR-ARW

-1

(Japanese) FR-ARWE

-1

(English) FR-ARWER

-1

(4 languages)

• Allows parameters set to application t o be read in batch and easily written to another high power factor converter.

• LCD and ten-key pad representations are available in three ways: Japanese, English and four languages (English, German, French, Spanish).

• Outline dimensions are the same as those of the FR-PU02

parameter unit.

-1

• Can also be used as the parameter unit.

12.7

(Unit: mm)

127

* The keys marked have different functions

from those for the FR-PU02

117

2-M3 screw

Ettective depth 4.5mm

-1

Accessory cover • When the parameter unit is removed from the high power factor converter, this cover

is fitted to that position. ποσιΑτιον

• This cover can be fitted and removed by a single action.

(Unit: mm)

127

70 12

This cover is supplied to the model which is not equipped with the parameter unit.

- 69 -

Name (Type) Specifications, Structure, Etc.

Parameter unit cable FR-CB L

Straight type

High power factor converter side

2-φ3.5

(Unit: mm)

Parameter unit side

Heat sink outside mounting attachment FR-ACN

L shape type

2-φ3.5

CBL 01

-0

High power factor converter side

-0

CBL-L1

Straight FR-CBL01 FR-CBL03 FR-CBL05

Type

FR-CBL-L1 FR-CBL-L3 FR-CBL-L5

Length (m)

1 3 5

• By using this attachment, the heat sink acting as the heat generator of the high power factor converter can be placed at the back of the control box. Since the converter-generated heat can be dissipated to the outside of the control box, the control box can be made compact.

• For the mounting state and panel cut dimensions, see the outline drawing (page 66). Note: Since the cooling fan exists in the cooling

section placed out of the box, do not use this attachment in environments subjected to water drops, oil mist, dust, etc.

Dimensions after mounting of the attachment

High power factor converter outline

Parameter un it si de

(Removable)

32.5

3.5

Spacer

(2.3)

The PU side connector of this L type cable ca be fixed with the accessory screws.

Type

FR-ACN01 FR-ACN02 FR-ACN03 FR-HC-7.5K FR-HC-H7.5K FR-ACN04 FR-HC-15K FR-HC-H15K FR-ACN05 FR-ACN06 FR-HC-30K FR-HC-H30K FR-ACN07 FR-ACN08 FR-HC-55K FR-HC-H55K

Type W W1 H H1 H2 H3 H4

FR-ACN01 150 125 336 320 8 8 17 FR-ACN02 150 125 336 320 8 8 17 FR-ACN03 220 195 336 320 8 8 17 FR-ACN04 280 230 554 530 12 12 122 FR-ACN05 330 280 604 580 12 12 122 FR-ACN06 340 290 682 625 19 38 122 FR-ACN07 460 410 625 590 15 20 80 FR-ACN08 490 430 775 730 17 28 80

Applicable High Power Factor Converter

200V class 400V class

–– ––

9.5

8.5 5

2-φ3.5

16.5

18.5

(Unit: mm)

- 70 -

Name (Type) Specifications, Structure, Etc.

Dirt-protection structure attachment FR-ACV

• By installing this option in the slits at the top, bottom, right and left of the high power factor converter, the high power factor converter can be changed to be an enclosed structure model (IP40). (The box-shaped attachment is added to the wiring section of 11K to 22K.)

• Adequate for wall mounting application, etc.IP40 (JEM1030): Structure which prevents a wire, copper band or the like in excess of 1mm in diameter or thickness from entering into the high

Type

FR-ACV01 FR-ACV02 FR-ACV03 FR-HC-7.5K FR-HC-H7.5K FR-ACV04 FR-HC-15K FR-HC-H15K FR-ACV05

power factor converter.

Note 1: T his struc ture is not protected from water and

fluid entry and is therefore not appropriate for environments often exposed to water drops or oily smoke.

Note 2:When this attachment is used, the

per miss ible am bient temperature of the high power factor converter is -10°C to +40°C.

Conduit connection attachment FR-AFN

• Used to connect a conduit pipe directly to the bottom of the high power factor converter.

• By installing this attachment, 11K to 55K (200V, 400V) are changed in structure specification to IP20. (IP00 is standard.) .

High power factor converter

Type

FR-AFN01 FR-AFN02 FR-AFN03 FR-AFN04 FR-AFN05 FR-HC-7.5K FR-HC-H7.5K FR-AFN06 FR-HC-15K FR-HC-H15K FR-AFN07 FR-AFN08 FR-HC-30K FR-HC-H30K FR-AFN09 FR-AFN10 FR-HC-55K FR-HC-H55K

Applicable High Power Factor Converter

200V class 400V class

–– ––

––

Applicable High Power Factor Converter

200V class 400V class

–– –– –– ––

–– ––

Radio noise filter FR-BIF 200V class FR-BIF-H 400V class

(Note)

2-φR hole

FR-AFN

N-φD hole

(with rubber bush)

(Installation pan el surｆace)

Note: Secured by a total of four places, the two

installation screws at the bottom of the high power factor converter and the two places at the bottom of the FR-AFN.

5 hole

(Unit: mm)

White

Red Blue Green Leakage current:4mA

Approx. 300

Attachment Outline Drawing (Unit: mm)

Type L H P N D M R

FR-AFN01 45 56 48 2 35 60 6 FR-AFN02 45 71 48 2 35 60 6 FR-AFN03 45 75 48 3 35 60 6 FR-AFN04 45 115 48 3 35 60 6 FR-AFN05 55 115 60 3 44 70 6 FR-AFN06 70 115 68 3 50 90 10 FR-AFN07 145 115 68 4 50 185 10 FR-AFN08 145 95 68 4 50 102.5 10 FR-AFN09 285 120 113 3 91 227.5 12 FR-AFN10 285 120 113 4 91 227.5 12

* Same dimensions as those of the high power factor converter.

NFB

Power supply

FR-BIF

Reactor 1

R S

29 7

Note: 1. This filter must not be connected to the

output circuit of the high power factor converter.

2.The cables should be as short as possible and connected to the terminal block of the high power factor converter.

- 71 -

Name (Type) Specifications, Structure, Etc.

Line noise filter FR-BLF

31.580

2.3

* (H) in a type code indicates that the unit is for 400V.

FR-BLF

130

160 180

(Unit: mm)

NFB

Power supply

Line noise filter

Note:1.Wind the cable 4 or more times in the same

direction in each phase. (A greater effect is produced as the winding times increase.)

2.If the cable size is too large to wind , use four or more filters in series and win d the cable in the same direction in each phase.

3.This filter can also be used on the output s ide as on the input side. The winding on the output side should be within 3 turns.

Reactor 1

R S T

- 72 -

APPENDIX

This chapter provides an “supplementary information” of this product. Always read the precautions, etc. before starting use.

APPENDIX 1 INSTRUCTIONS FOR COMPLIANCE WITH THE EUROPEAN

STANDARDS................................................................................ 73

APPENDIX 2 Instructions for UL and cUL........................................ .............. 74

APPENDIX 1 INSTRUCTIONS FOR COMPLIANCE WITH THE EUROPEAN

STANDARDS

(The products conforming to the Low Voltage Directive carry the CE mark.)

Low Voltage Directive for FR-HC series (High power factor converters)

(1) Our view of the FR-HC series for the Low Voltage Directive.

The FR-HC series is covered by the Low Voltage Directive ( DIN VDE0160 ).

(2) Compliance

* We have self-confirmed the FR-HC series as products compliant to the Low Voltage Directive. * Since the FR-HCB box, FR-HCL01 reactor and FR- HCL02 reactor a re considered p ar ts of the FR- HC

unit and we place the CE mark on the FR-HC unit.

(3) Outline of instruction

* In the FR-HC-H series (40 0V class ), the rated in put voltage range is three -phase, 380 V to 415V, 50Hz/

60Hz.

* Connect the equipment to the earth securely. Do not use an earth leakage circuit breaker as an electric

shock protector without connecting the equipment to the earth. * Wire the earth terminal independently. (Do not connect two or more cables to one terminal.) * The wire size for PVC cables are shown for the following conditions;

Ambient Temperature: 40°C maximum Wire installation: On wall without ducts or conduits

If conditions are different from ab ove, select appropria te wire accord ing to E N60204 A NNEX C, TABL E

* On the input side, use the recommended no-fuse breaker and magnetic contactor which conform to the

EN or IEC standard. * Use the FR-HC un it, including th e FR-HCB box and the react ors, under the condit ions of overvoltage

category II and contamination lev el 2 or less set forth in IEC664.

(a) To meet the overvoltage categor y II, inser t an EN or IEC stand ard-compliant isolat ion transformer

or surge suppressor in the input of the FR-HC (FR-HCL01 reactor).

(b) To meet the con tamination level 2, install the FR -HC unit, the FR-HCB box and the r eactors in a

control box protected against ingress of water, oil, carbon, dust, etc. (IP54 or higher).

* The operating capaci ty of the relay outputs (termina l symbol A, B, C) should be 30VDC, 0.3A. ( The

relay outputs are basically isolated from the terminal circuitry of the FR-HC unit.)

- 73 -

APPENDIX 2 Instructions for UL and cUL

(Standard to comply with: UL 508C, CSA C22.2 No. 14)

1. General Precaution

The bus capacitor discharge tim e is 10 minutes. Before starting wiring or inspec ti on, switch power off, wait for more than 10 minutes, and check for residual voltage between P and N with a meter etc., to avoid a hazard of electrical shock.

2. Installation

(1) T he FR-HC units have been approved as products for use in an enclosure. Please refer to the following

UL’s requirement for the enclosure. * The minimum enclosure size is 150 pe rce nt of ea ch conver ter an d inverter combination, whic h mus t be

provided with ventilation openings on each side near the top. * The minimum area for the ventilatio n openings must be 55 percent of th e overall surface area of each

side and be located i n the top quarter of the s ide. The maximum width of eac h individua l vent must be

3.17mm (1 / 8 in.).

(2) The FR-HC-H55K have been approved on the following condition.

* A 2.8 m

H55K. *Two 2.8 m

the following illustrations.

/min {100 cfm } fan must be used space d 10cm (4 in.) ab ove the FR-HC-H55K and FR-HCB-

/min {100 cfm } fans for air ci rculation for the FR-HCL02 -H55K must be used as shown in

Top view

10 to 20 cm (4 to 8 in.)

Front view

10 to 20 cm (4 to 8 in.)

3. Branch circuit protection

For installation in United States, branch circuit protection must be provided, in accordance with the National Electrical Code and any applicable local codes. For installation in Canada, branch circuit protection must be provided in accordance with the Canada Electrical Code and any applicable provincial codes.

4. Short circuit ratings

Suitable For Use in A Circuit Capable Of Delivering Not More Than 5 kA r ms Symmetr ical Ampere s, 500 Volts Maximum.

5. Wiring

When wiring t he I/O terminals and control circuit, use UL-approved, 75°C or higher rated copper wires and round crimping terminals and screw them to the specified tightening torque . Crimp the crimping terminals with the crimping tool recommended by the terminal maker.

- 74 -

REVISIONS

* The manual number is given on the bottom left of the back cover.

Print Date

Dec., 1996 IB(NA)66718-A First edition

Mar., 2001 IB(NA)66718-B

Apr., 2003 IB(NA)66718-C

Sep., 2008 IB(NA)66718-D

*Manual Number

Additions

• Applicable inverters

• Instructions for Compliance with the European Standards (Appendix 1)

• Instructions for Compliance with U.S. and Canadian Electrical Codes (Appendix 2)

Partial additions

•Wiring

Partial additions

• Not e for terminal connection diagram

Partial changes

• Converter reset

Revision

IB(NA)66718-D

- 75 -

Mitsubishi Electronics FR-A500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY INSTRUCTIO NS

CONTENTS

1. OVERVIEW

1.1 PRECAUTIONS FOR OPERATION

1.1.1 Japanese harmonic suppression guideline

1.1.2 Pre-operation procedure

1.1.3 Handling precautions

1.2 STRUCTURE

1.2.1 Structure

1.2.2 Removal and reinstallation of the front cover

1.2.3 Removal and reinstallation of the accessory cover

1.2.4 Removal and reinstallation of the parameter unit (FR-PU02)

1.3 INSTALLATION AND WIRING

1.3.1 Precautions for installation (1) Installation of the high power factor converter

1.3.2 Wiring instructions

1.3.3 Wiring of the main circuit

1.3.4 Wiring of the control circuit

2. PARAMETERS

2.1 PARAMETER UNIT

2.1.1 Structure of the parameter unit

2.1.2 Setting and changing the parameter values

2.2 PARAMETER FUNCTION DETAILS

2.2.1 Parameter list

2.2.2 Setting of parameters to improve the corresponding operational functions

Pr.22 “overload signal detection level”

Pr.40 “output terminal assignment”

Pr.57 “restart selection”

Pr.77 “parameter write disable selection”

Pr.900 “FM terminal calibration”

2.3 HELP FUNCTIONS

2.3.1 Definitions of the help function displays (1) Monitoring function

2.4 CONVERTER RESET

3. PROTECTIVE FUNCTIONS

3.1 E RRORS

3.1.1 Error (alarm) definitions and remedies

3.1.2 Faults and check points

3.2 MAINTENANCE AND INSPECTION

3.2.1 Precautions for maintenance and inspection

3.2.2 Check items (1) Daily inspection

3.2.3 Replacement of parts

3.2.4 Measurement of main circuit voltages, currents and powers

4. PRECAUTIONS FOR SELECTION

4.1 PRECAUTIONS FOR SELECTING PERIPHERAL DEVICES

4.1.1 Measures against noises

4.1.2 Peripheral device list

4.1.3 Selecting the rated sensitivity current for the earth leakage circuit breaker

5. SPECIFICATIONS

5.1 SPECIFICATIONS

5.1.1 Standard specifications

5.1.2 Block diagram

5.1.3 Terminals

5.1.4 Terminal block arrangement

5.1.5 Outline drawings (400V class models have H in their type codes) (1) High power factor converter (FR-HC)

5.1.6 Panel cutting dimension diagrams (For use of the heat sink outside mounting attachment)

5.1.7 Parameter unit (FR-PU02-1/FR-PU02E-1/FR-PU02ER-1) dimension diagram

5.2 OPTIONS

5.2.1 Option list

5.2.2 External dedicated options

APPENDIX

APPENDIX 2 Instructions for UL and cUL

REVISIONS