Mitsubishi FR-A520-0.4K-NA, FR-A520-55K-NA, FR-A520-22K-NA, FR-A520-37K-NA, FR-A520-7.5K-NA Instruction Manual

...

TRANSISTORIZED INVERTER

INSTRUCTION MANUAL

FR-A500

OUTLINE

Chapter 1

INSTALLATION

AND WIRING

Chapter 2

OPERATION

/CONTROL

Chapter 3

PARAMETERS

Chapter 4

PROTECTIVE

FUNCTIONS

Chapter 5

SPECIFICATIONS

Chapter 7

PRECAUTIONS FOR

MAINTENANCE AND

INSPECTION

Chapter 6

FR-A520-0.4K to 55K-NA FR-A540-0.4K to 55K-NA,-EC

HIGH FUNCTION

LOW ACOUSTIC NOISE

FR-A500-NA,-EC

TRANSISTORIZED INVERTER

INSTRUCTION MANUAL

Thank you for choosing this Mitsubishi transistorized Inverter. This instruction manual gives handling information and precautions for use of this equipment. Incorrect handling might cause an unexpected fault. Before using the inverter, please read this manual carefully to use the equipment to its optimum. Please forward this manual to the end user. This instruction manual uses the International System of Units (SI). The measuring units in the yard and pound system are indicated in parentheses as reference values.

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have read through this instruction manual and appended documents carefully and can use the equipment correctly. Do not use the inverter until you have a full knowledge of the equipment, safety information and instructions. In this instruction manual, the safety instruction levels are classified into "WARNING" and "CAUTION".

WARNING

CAUTION

Note that the level may lead to a serious consequence according to conditions. Please follow the instructions of both levels because they are important to personnel safety.

CAUTION

Assumes that incorrect handling may cause hazardous conditions, resulting in death or severe injury.

Assumes that incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause physical damage only.

1. Electric Shock Prevention

WARNING

 While power is on or when the inverter is running, do not open the front cover. You may get an electric shock.  Do not run the inverter with the front cover removed. Otherwise, you may access the exposed high-voltage terminals or the

charging part of the circuitry and get an electric shock.

 Even if power is off, do not remove the front cover except for wiring or periodic inspection. You may access the charged inverter

circuits and get an electric shock.

 Before starting wiring or inspection, check to make sure that the inverter power indicator lamp is off, wait for at least 10 minutes

after the power supply has been switched off, and check that there are no residual voltage using a tester or the like. The capacitor is charged with high voltage for some time after power off and it is dangerous.

 This inverter must be earthed (grounded). Earthing (grounding) must conform to the requirements of national and local safety

regulations and electrical code. (JIS, NEC section 250, IEC 536 class 1 and other applicable standards)

 Any person who is involved in the wiring or inspection of this equipment should be fully competent to do the work.  Always install the inverter before wiring. Otherwise, you may get an electric shock or be injured.  Perform setting dial and key operations with dry hands to prevent an electric shock.  Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Otherwise, you may get an electric shock.  Do not change the cooling fan while power is on. To do so will invite a hazardous condition.

2. Fire Prevention

CAUTION

 Mount the inverter on an incombustible surface. Installing the inverter directly on or near a combustible surface could lead to a fire.  If the inverter has become faulty, switch off the inverter power. A continuous flow of large current could cause a fire.  When using a brake resistor, make up a sequence that will turn off power when an alarm signal is output. Otherwise, the brake

resistor may excessively overheat due to damage of the brake transistor and such, causing a fire.

 Do not connect a resistor directly to the DC terminals P/+, N/-. This could cause a fire.

3. Injury Prevention

CAUTION

 Apply only the voltage specified in the instruction manual to each terminal to prevent damage etc.  Ensure that the cables are connected to the correct terminals. Otherwise, damage etc. may occur.  Always make sure that polarity is correct to prevent damage etc.  While power is on and for some time after power-off, do not touch the inverter as it is hot and you may get burnt.

A-1

4. Additional Instructions

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

(1) Transportation and installation

CAUTION

 When carrying products, use correct lifting gear to prevent injury.  Do not stack the inverter boxes higher than the number recommended.  Ensure that installation position and material can withstand the weight of the inverter. Install according to the information in the

Instruction Manual.

 Do not operate if the inverter is damaged or has parts missing.  Do not hold the inverter by the front cover; it may fall off.  Do not stand or rest heavy objects on the inverter.  Check the inverter mounting orientation is correct.  Prevent screws, wire fragments, conductive bodies, oil or other flammable substances from entering the inverter.  Do not drop the inverter, or subject it to impact.  Use the inverter under the following environmental conditions:

Ambient temperature

Ambient humidity 90%RH or less (non-condensing) Storage temperature -20°C to +65°C* (-4°F to 149°F) Ambience Indoors (free from corrosive gas, flammable gas, oil mist, dust and dirt)

Environment

Altitude, vibration

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

(2) Wiring

-10°C to +50°C (14°F to 122°F) (non-freezing) (-10°C to +40°C with totally ecclosed structure specification attachment (FR-A5CV)) (14°F to 104°F)

Maximum 1000m (3280.80 feet.) above sea level for standard operation. After that derate by 3% for every extra 500m(1640.40 feet.) up to 2500m(8202.00 feet.) (91%).

or less (conforming to JIS C 60068-2-6)

5.9 m/s

CAUTION

 Do not fit capacitive equipment such as a power factor correction capacitor, surge suppressor or radio noise filter (option FR-BIF)

to the inverter output side.

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

(3) Trial run

CAUTION

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

(4) Operation

WARNING

 When you have chosen the retry function, stay away from the equipment as it will restart suddenly after an alarm stop.  The [STOP] key is valid only when the appropriate function setting has been made. Prepare an emergency stop switch separately.  Make sure that the start signal is off before resetting the inverter alarm. A failure to do so may restart the motor suddenly.  The load used should be a three-phase induction motor only. Connection of any other electrical equipment to the inverter output

may damage the equipment.

 Do not modify the equipment.  Do not perform parts removal which is not instructed in this manual. Doing so may lead to fault or damage of the inverter.

CAUTION

 The electronic thermal relay function does not guarantee protection of the motor from overheating.  Do not use a magnetic contactor on the inverter input for frequent starting/stopping of the inverter.  Use a noise filter to reduce the effect of electromagnetic interference. Otherwise nearby electronic equipment may be affected.  Take measures to suppress harmonics. Otherwise power supply harmonics from the inverter may heat/damage the power capacitor

and generator.

 When a 400V class motor is inverter-driven, please use an insulation-enhanced motor or measure taken to suppress surge

voltages. Surge voltages attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor.

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

before starting operation.

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

machine.

 In addition to the inverter's holding function, install a holding device to ensure safety.  Before running an inverter which had been stored for a long period, always perform inspection and test operation.

A-2

(5) Emergency stop

CAUTION

 Provide a safety backup such as an emergency brake which will prevent the machine and equipment from hazardous conditions if

the inverter fails.

 When the breaker on the inverter primary side trips, check for the wiring fault (short circuit), damage to internal parts of the inverter,

etc. Identify the cause of the trip, then remove the cause and power on the breaker.

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

(6) Maintenance, inspection and parts replacement

CAUTION

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

(7) Disposing of the inverter

CAUTION

 Treat as industrial waste.

(8) General instructions

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

A-3

CONTENTS

CHAPTER 1 OUTLINE 1

1.1 Pre-Operation Information .................................................................................. 2

1.1.1 Precautions for operation ...................................................................................................................2

1.2 Basic Configuration............................................................................................. 3

1.2.1 Basic configuration.............................................................................................................................3

1.3 Structure ............................................................................................................... 4

1.3.1 Appearance and structure..................................................................................................................4

1.3.2 Removal and reinstallation of the front cover.....................................................................................5

1.3.3 Removal and reinstallation of the operation panel .............................................................................7

CHAPTER 2 INSTALLATION AND WIRING 9

2.1 Installation .......................................................................................................... 10

2.1.1 Instructions for installation................................................................................................................10

2.2 Wiring.................................................................................................................. 12

2.2.1 Terminal connection diagram...........................................................................................................12

2.2.2 Wiring of the main circuit..................................................................................................................15

2.2.3 Wiring of the control circuit...............................................................................................................21

2.2.4 Connection to the PU connector ......................................................................................................25

2.2.5 Connection of stand-alone option units............................................................................................28

2.2.6 Design information ...........................................................................................................................33

2.3 Other wiring........................................................................................................ 34

2.3.1 Power supply harmonics ..................................................................................................................34

2.3.2 Inverter-generated noises and their reduction techniques ...............................................................34

2.3.3 Leakage currents and countermeasures..........................................................................................37

2.3.4 Inverter-driven 400V class motor .....................................................................................................38

2.3.5 Peripheral devices............................................................................................................................39

2.3.6 Instructions for UL and cUL..............................................................................................................42

2.3.7 Instructions for compliance with the European Directives................................................................43

2.3.8 Earthing (EC version).......................................................................................................................45

CHAPTER 3 OPERATION/CONTROL 47

3.1 Pre-Operation Information ................................................................................ 48

3.1.1 Devices and parts to be prepared for operation...............................................................................48

3.1.2 Power on ..........................................................................................................................................50

3.2 Operation Panel ................................................................................................. 51

3.2.1 Names and functions of the operation panel (FR-DU04) .................................................................51

3.2.2 Monitor display changed by pressing the key .................................................................................52

3.2.3 Monitoring.........................................................................................................................................52

3.2.4 Frequency setting.............................................................................................................................52

3.2.5 Parameter setting method................................................................................................................53

3.2.6 Operation mode................................................................................................................................54

3.2.7 Help mode........................................................................................................................................54

3.2.8 Copy mode.......................................................................................................................................56

3.3 Operation ............................................................................................................ 57

3.3.1 Pre-operation checks .......................................................................................................................57

3.3.2 External operation mode (Operation using external input signals)...................................................58

3.3.3 PU operation mode

(Operation using the operation panel (FR-DU04)) ..........................................................................59

3.3.4 Combined operation mode

(Operation using the external input signals and PU)........................................................................60

CHAPTER 4 PARAMETERS 61

4.1 Parameter Lists ..................................................................................................62

4.1.1 Parameter lists .................................................................................................................................62

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

4.1.3 Parameters recommended to be set by the user .............................................................................70

4.2 Parameter Function Details .............................................................................. 71

4.2.1 Torque boost (Pr. 0, Pr. 46, Pr. 112)................................................................................................71

4.2.2 Output frequency range (Pr. 1, Pr. 2, Pr. 18) ...................................................................................72

4.2.3 Base frequency, base frequency voltage (Pr. 3, Pr. 19, Pr. 47, Pr. 113) .........................................73

4.2.4 Multi-speed operation (Pr. 4 to Pr. 6, Pr. 24 to Pr. 27, Pr. 232 to Pr. 239).......................................74

4.2.5 Acceleration/deceleration time (Pr. 7, Pr. 8, Pr. 20, Pr. 21, Pr. 44, Pr. 45, Pr. 110, Pr. 111)..........75

4.2.6 Electronic overcurrent protection (Pr. 9)...........................................................................................76

4.2.7 DC injection brake (Pr. 10 to Pr. 12) ................................................................................................77

4.2.8 Starting frequency (Pr. 13) ...............................................................................................................78

4.2.9 Load pattern selection (Pr. 14).........................................................................................................79

4.2.10 Jog operation (Pr. 15, Pr. 16)...........................................................................................................80

4.2.11 MRS input selection (Pr. 17) ............................................................................................................81

4.2.12 Stall prevention (Pr. 22, Pr. 23, Pr. 66, Pr. 148, Pr. 149, Pr. 154)....................................................82

4.2.13 Multi-speed input compensation (Pr. 28)..........................................................................................83

4.2.14 Acceleration/deceleration pattern (Pr. 29, Pr. 140 to Pr. 143)..........................................................84

4.2.15 Regenerative brake duty (Pr. 30, Pr. 70)..........................................................................................85

4.2.16 Frequency jump (Pr. 31 to Pr. 36)....................................................................................................86

4.2.17 Speed display (Pr. 37, Pr. 144) ........................................................................................................87

4.2.18 Up-to-frequency sensitivity (Pr. 41)..................................................................................................88

4.2.19 Output frequency detection (Pr. 42, Pr. 43, Pr. 50, Pr. 116) ............................................................88

4.2.20 Second/third stall prevention (Pr. 48, Pr. 49, Pr. 114, Pr. 115) ........................................................89

4.2.21 Monitor display/FM, AM terminal function selection (Pr. 52 to Pr. 54, Pr. 158)................................90

4.2.22 Monitoring reference (Pr. 55, Pr. 56)................................................................................................93

4.2.23 Automatic restart after instantaneous power failure (Pr. 57, Pr. 58, Pr. 162, Pr. 165, Pr. 611).......94

4.2.24 Remote setting function selection (Pr. 59) .......................................................................................96

4.2.25 Intelligent mode selection (Pr. 60)....................................................................................................98

4.2.26 Acceleration/deceleration reference current (Pr. 61 to Pr. 64) .......................................................100

4.2.27 Retry function (Pr. 65, Pr. 67 to Pr. 69) ..........................................................................................101

4.2.28 Applied motor (Pr. 71) ....................................................................................................................103

4.2.29 PWM carrier frequency (Pr. 72, Pr. 240)........................................................................................104

4.2.30 Voltage input (Pr. 73) .....................................................................................................................105

4.2.31 Input filter time constant (Pr. 74) ....................................................................................................106

4.2.32 Reset selection/disconnected PU detection/PU stop selection (Pr. 75).........................................106

4.2.33 Alarm code output selection (Pr. 76)..............................................................................................108

4.2.34 Parameter write disable selection (Pr. 77) .....................................................................................109

4.2.35 Reverse rotation prevention selection (Pr. 78) ...............................................................................110

4.2.36 Operation mode selection (Pr. 79) .................................................................................................111

4.2.37 Motor capacity/number of motor poles/speed control gain (Pr. 80, Pr. 81, Pr. 89) ........................114

4.2.38 Offline auto tuning function (Pr. 82 to Pr. 84, Pr. 90 to Pr. 94, Pr. 96) ...........................................115

4.2.39 Online auto tuning selection (Pr. 95)..............................................................................................123

Contents

4.2.40 V/F control frequency (voltage) (Pr. 100 to Pr. 109).......................................................................125

4.2.41 Computer link operation (Pr. 117 to Pr. 124, Pr. 342)....................................................................126

4.2.42 PID control (Pr. 128 to Pr. 134)......................................................................................................137

4.2.43 Commercial power supply-inverter switchover function (Pr. 135 to Pr. 139)..................................144

4.2.44 Output current detection function (Pr. 150, Pr. 151).......................................................................149

4.2.45 Zero current detection (Pr. 152, Pr. 153)........................................................................................150

4.2.46 RT signal activated condition selection (Pr. 155) ...........................................................................151

4.2.47 Stall prevention function and current limit function (Pr. 156)..........................................................151

4.2.48 OL signal output timer (Pr. 157) .....................................................................................................153

4.2.49 User group selection (Pr. 160, Pr. 173 to Pr. 176) .........................................................................154

4.2.50 Watt-hour meter clear/actual operation hour meter clear (Pr. 170, Pr. 171) ..................................155

4.2.51 Input terminal function selection (Pr. 180 to Pr. 186) .....................................................................155

4.2.52 Output terminal function selection (Pr. 190 to Pr. 195) ..................................................................158

4.2.53 User initial value setting (Pr. 199) ..................................................................................................160

4.2.54 Programmed operation function (Pr. 200 to Pr. 231) .....................................................................161

4.2.55 Cooling fan operation selection (Pr. 244).......................................................................................165

4.2.56 Stop selection (Pr. 250)..................................................................................................................166

4.2.57 Output phase failure protection selection (Pr. 251)........................................................................167

4.2.58 Override bias/gain (Pr. 252, Pr. 253)..............................................................................................167

4.2.59 Power failure-time deceleration-to-stop function (Pr. 261 to Pr. 266) ............................................168

4.2.60 Stop-on-contact, load torque high-speed frequency selection (Pr. 270) ........................................169

4.2.61 High-speed frequency control (Pr. 271 to Pr. 274).........................................................................170

4.2.62 Stop-on-contact control function (Pr. 275, Pr. 276)........................................................................174

4.2.63 Brake sequence function (Pr. 278 to Pr. 285) ................................................................................177

4.2.64 Droop control (Pr. 286, Pr. 287) .....................................................................................................181

4.2.65 Capacitor life alarm (Pr. 503, Pr. 504)............................................................................................182

4.2.66 FM / AM terminal calibration (Pr. 900, Pr. 901).............................................................................183

4.2.67 Frequency setting voltage (current) bias and gain (Pr. 902 to Pr. 905)..........................................185

4.2.68 PU buzzer control (Pr. 990)............................................................................................................190

CHAPTER 5 PROTECTIVE FUNCTIONS 191

5.1 Errors (Alarms)................................................................................................ 192

5.1.1 Error (alarm) definitions..................................................................................................................192

5.1.2 To know the operating status at the occurrence of an alarm .........................................................201

5.1.3 Correspondences between digital and actual characters...............................................................201

5.1.4 Alarm code output ..........................................................................................................................202

5.1.5 Resetting the inverter .....................................................................................................................202

5.2 Troubleshooting...............................................................................................203

5.2.1 Motor remains stopped...................................................................................................................203

5.2.2 Motor rotates in opposite direction .................................................................................................203

5.2.3 Speed greatly differs from the setting.............................................................................................203

5.2.4 Acceleration/deceleration is not smooth.........................................................................................203

5.2.5 Motor current is large .....................................................................................................................203

5.2.6 Speed does not increase................................................................................................................204

5.2.7 Speed varies during operation .......................................................................................................204

5.2.8 Operation mode is not changed properly .......................................................................................204

5.2.9 Operation panel (FR-DU04) display is not provided.......................................................................204

5.2.10 POWER lamp is not lit....................................................................................................................204

5.2.11 Parameter write cannot be performed............................................................................................204

III

CHAPTER 6 PRECAUTIONS FOR MAINTENANCE AND INSPECTION 205

6.1 Precautions for maintenance and inspection ............................................... 206

6.1.1 Precautions for maintenance and inspection .................................................................................206

6.1.2 Check items....................................................................................................................................206

6.1.3 Periodic inspection .........................................................................................................................206

6.1.4 Insulation resistance test using megger.........................................................................................207

6.1.5 Pressure test ..................................................................................................................................207

6.1.6 Daily and periodic inspection..........................................................................................................207

6.1.7 Replacement of parts .....................................................................................................................210

6.1.8 Inverter replacement ......................................................................................................................211

6.1.9 Measurement of main circuit voltages, currents and powers .........................................................212

CHAPTER 7 SPECIFICATIONS 215

7.1 Standard Specifications.................................................................................. 216

7.1.1 Model specifications.......................................................................................................................216

7.1.2 Common specifications ..................................................................................................................218

7.1.3 Outline dimension drawings ...........................................................................................................220

CHAPTER 8 OPTIONS 225

Contents

8.1 Option List ........................................................................................................ 226

8.1.1 Stand-alone options .......................................................................................................................226

8.1.2 Plug-in dedicated options...............................................................................................................228

APPENDICES 239

Appendix1 Instruction Code List............................................................................ 240

Appendix2 Operating the Inverter Using a Single-Phase Power Supply ............. 247

CHAPTER 1

OUTLINE

This chapter gives information on the basic "outline" of this product. Always read the instructions in this chapter before using the equipment.

1.1 Pre-Operation Information ....................................... 2

1.2 Basic Configuration ................................................. 3

1.3 Structure.................................................................. 4

•DU Operation panel (FR-DU04)

•PU Operation panel (FR-DU04) and parameter unit (FR-PU04)

•Inverter Mitsubishi transistorized inverter FR-A500 series

•Pr. Parameter number

• PU operation Operation using the PU (FR-DU04/FR-PU04)

• External operation Operation using the control circuit signals

• Combined operation Operation using both the PU (FR-DU04/FR-PU04) and external operation

•FR-A200E Mitsubishi transistorized inverter FR-A200 series

<EXCELLENT> series

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

OUTLINE

1.1 Pre-Operation Information

1.1.1 Precautions for operation

Incorrect handling might cause the inverter to operate improperly, its life to be reduced considerably, or at the worst, the inverter to be damaged. Handle the inverter properly in accordance with the information in each section as well as the precautions and instructions of this manual to use it correctly. This manual is written for the FR-A500 series transistorized inverters. For handling information on the parameter unit (FR-PU04), plug-in options, stand-alone options, etc., refer to the corresponding manuals.

(1) Unpacking and product check

Unpack the inverter and check the capacity plate on the front cover and the rating plate on the inverter side face to ensure that the product agrees with your order and the inverter is intact.

1) Inverter type

Capacity plate

FR-A520-0.4K

Input rating

Output rating

MITSUBISHI

MODEL

INPUT :

OUTPUT :

Rating plate

FR-A520-0.4K

XXXXX

INVERTER

Inverter typ

Inverter type

FR- A520 - 0.4K

Voltage Class

Symbol

A520

200V class

A540

400V class

Serial number

Capacity plate

Applicable Motor Capacity

Symbol

0.4K to 55K Indicates capacity in "kW".

Serial number

Rating plate

Symbol

NA U.S. specifications EC European specifications

Specifications

SERIAL :

PASSED

2) Accessory Instruction manual

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

(2) Preparations of instruments and parts required for operation

Instruments and parts to be prepared depend on how the inverter is operated. Prepare equipment and parts as necessary. (Refer to page 48.)

(3) Installation

To operate the inverter with high performance for a long time, install the inverter in a proper place, in the correct direction, and with proper clearances. (Refer to page 10.)

(4) Wiring

Connect the power supply, motor and operation signals (control signals) to the terminal block. Note that incorrect connection may damage the inverter and peripheral devices. (Refer to page 12.)

OUTLINE

1.2 Basic Configuration

1.2.1 Basic configuration

The following devices are required to operate the inverter. Proper peripheral devices must be selected and correct connections made to ensure proper operation. Incorrect system configuration and connections can cause the inverter to operate improperly, its life to be reduced considerably, and in the worst case, the inverter to be damaged. Please handle the inverter properly in accordance with the information in each section as well as the precautions and instructions of this manual. (For connections of the peripheral devices, refer to the corresponding manuals.)

Name Description

Power supply

Earth leakage circuit breaker (ELB) or moulded

(MCCB)

(ELB)

(MC)

C reactor

(FR-BAL)

DC reactor

(FR-BEL)

Earth

(Ground)

Earth

(Ground)

case circuit breaker (MCCB)

Magnetic contactor

Reactors

Inverter

Devices connected to the output

Earth (Ground)

Use the power supply within the permissible power supply specifications of the inverter. (Refer to page 216.)

The breaker should be selected with care since a large inrush current flows in the inverter at power on. (Refer to page 39.)

Install the magnetic contactor to ensure safety. (Refer to page 41) Do not use this magnetic contactor to start and stop the inverter. Doing so will cause the inverter life to be shorter. (Refer to page 39.)

The reactors must be used when the power factor is to be improved or the inverter is installed near a large power supply system (1000kVA or more and wiring distance within 10m (32.81 feet)). Make selection carefully.

• The life of the inverter is influenced by ambient temperature. The ambient temperature should be as low as possible within the permissible range. This must be noted especially when the inverter is installed in an enclosure. (Refer to page 10.)

• Wrong wiring might lead to damage of the inverter. The control signal lines must be kept fully away from the main circuit to protect them from noise. (Refer to page

12.)

• Do not install a power factor correction capacitor, surge suppressor or radio noise filter on the output side.

• When installing a moulded case circuit breaker (MCCB) on the output side of the inverter, contact each manufacturer for selection of the moulded case circuit breaker.

To prevent an electric shock, always earth (ground) the motor and inverter. For reduction of induction noise from the power line of the inverter, it is recommended to wire the earth (ground) cable by returning it to the earth (ground) terminal of the inverter. (Refer to page 36.)

1.3 Structure

1.3.1 Appearance and structure

OUTLINE

(1) Front view

POWER lamp

ALARM lamp

Operation panel (FR-DU04)

Brake resistor* (Fitted to the back)

Accessory cover

Wiring port cover for option (DATA PORT)

Front cover

Rating plate

Capacity plate

(2) Without front cover

PU connector (Provided with modular jack type relay connector) (For use with RS-485 cable communication)

Modular jack type relay connector compartment

Inboard option mounting positions

Control circuit terminal block

Main circuit terminal block

Wiring cover

*7.5K or less inverters are equipped with an inboard brake resistor.

Note: The "EC" version of the FR-A500 uses pheonix type connectors for the control circuit terminal block.

Lamp indication

Power lamp . . . . . . . . . . . . . . . .Lights when power is supplied to the control circuit (R1, S1).

Alarm lamp . . . . . . . . . . . . . . . .Lights when the inverter is in the alarm status (major faults).

1.3.2 Removal and reinstallation of the front cover

FR-A520-0.4K to 11K-NA, FR-A540-0.4K to 7.5K-NA/-EC

• Removal

1) Hold both sides of the front cover top and push the front cover down.

2) Hold down the front cover and pull it toward you to remove. (The front cover may be removed with the PU (FR-DU04/FR-PU04) on.)

hook

OUTLINE

Front cover

• Reinstallation

1) Insert the hooks at the bottom of the front cover into the sockets of the inverter.

2) Using the hooks as supports, securely press the front cover against the inverter.

Note:When the operation panel is fitted to the removed front cover, reinstall the front cover after

removing the operation panel.

Inverter

FR-A520-15K to 22K-NA, FR-A540-11K to 22K-NA/-EC

• Removal

1) Remove the installation screw at top of the front cover.

2) Hold both ends of the front cover top.

3) Pull the front cover toward you to remove. (The front cover may be removed with the PU (FR-DU04/FR-PU04) on.)

• Reinstallation

1) Insert the hooks at the front cover bottom into the sockets of the inverter.

2) Using the hooks as supports, securely press the front cover against the inverter.

3) Fix the front cover with the top screw.

Note:When the operation panel is fitted to the removed front cover, reinstall the front cover after

removing the operation panel.

FR-A520-30K to 55K-NA, FR-A540-30K to 55K-NA/-EC

• Removal

1) Remove installation screws on the front cover.

• Reinstallation

1) Fix the front cover with the installation screws.

OUTLINE

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

2. The same serial number is printed on the capacity plate of the front cover and the rating plate of the inverter. Before reinstalling the front cover, check the serial number to ensure that the cover removed is reinstalled to the inverter from where it was removed.

REMARKS

• Removal of the wiring port cover for option (DATA PORT) Push the option wiring port cover for option (DATA PORT) from the back of the front cover to remove before fitting the communication option.

Wiring port cover for option (DATA PORT)

OUTLINE

1.3.3 Removal and reinstallation of the operation panel

To ensure safety, remove and reinstall the operation panel after powering off.

• Removal Hold down the top button of the operation panel and pull the operation panel toward you to remove.

Removal

Reinstallation

When reinstalling the operation panel, insert it straight and reinstall it securely.

• Reinstallation using the connection cable

1) Remove the operation panel.

2) Disconnect the modular jack type relay connector. (Place the disconnected modular jack type relay

connector in the modular jack type relay connector compartment.)

Modular jack type relay connector

Modular jack type relay connector compartment

3) Securely plug one end of the connection cable into the PU connector (modular jack type relay

connector) of the inverter and the other end into the operation panel. (Refer to page 25 for the connection cable.)

Note: Install the operation panel only when the front cover is on the inverter.

MEMO

CHAPTER 2

INSTALLATION AND WIRING

This chapter explains the basic "installation and wiring" for use of this product. Always read the instructions and other information before using the equipment.

2.1 Installation .............................................................10

2.2 Wiring ....................................................................12

2.3 Other wiring ...........................................................34

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

INSTALLATION AND WIRING

2.1 Installation

2.1.1 Instructions for installation

1) Handle the unit carefully. The inverter uses plastic parts. Handle it gently to protect it from damage. Also, hold the unit with even strength and do not apply too much strength to the front cover alone.

2) Install the inverter in a place where it is immune to vibration. (5.9 m/s Also note the cart, press, etc.

3) Note on ambient temperature The life of the inverter is under great influence of ambient temperature. In the place of installation, ambient temperature must be within the permissible range (-10

°C to +50°C (14°F to 122°F)). Check that the

ambient temperature is within that range in the positions shown in figure 3).

4) Install the inverter on a non-combustible surface. The inverter will be very hot (maximum about 150

°C (302°F)). Install it on a non-combustible surface (e.g.

metal). Also leave sufficient clearances around the inverter.

5) Avoid high temperature and high humidity. Avoid direct sunlight and places of high temperature and high humidity.

6) The amount of heat generated in an enclosure can be reduced considerably by placing the heatsink outside the enclosure.

or less)

Note: 1. Use the option (FR-A5CN) for installation. The mounting area should be cut to the panel

cutting dimensions.

2. The cooling section outside the enclosure has the cooling fan. Do not use the inverter in any environment where it is exposed to waterdrops, oil mist, dust, etc.

7) Avoid places where the inverter is exposed to oil mist, flammable gases, fluff, dust, dirt etc. Install the inverter in a clean place or inside a "totally enclosed" panel, which does not accept any suspended matter.

8) Note the cooling method when the inverter is installed in an enclosure. When two or more inverters are installed or a ventilation fan is mounted in an enclosure, the inverters and ventilation fan must be installed in proper positions with extreme care taken to keep the ambient temperatures of the inverters below the permissible value. If they are installed in improper positions, the ambient temperatures of the inverters will rise and ventilation effect will be reduced.

9) Install the inverter securely in the vertical direction with screws or bolts.

3) Note on ambient temperature 4) Clearances around the inverter

5cm

(1.97 inches)

5cm

(1.97 inches )

Measurement position

5cm (1.97 inches)

10cm (3.94 inches) or more

5cm (1.97 inches)

or more *

10cm (3.94 inches) or more

5cm (1.97 inches)

or more *

Leave sufficient clearances above and under the inverter to ensure adequate ventilation.

Cooling fan built in the inverter

Cooling air

*: 1cm (0.39 inches) or more for model 3.7K or less These clearances are also necessary for changing the cooling fan.

(

The

2.2K or more for 400V cl ass are

provided with a cooling fan.)

8) For installation in an enclosure

INSTALLATION AND WIRING

Ventilation fan

(Correct example)

Inverter Inverter

(Incorrect example)

Position of Ventilation Fan

Inverter

Built-in cooling fan

(Correct example)

Inverter

Accommodation of two or more inverters

Inverter

(Incorrect example)

9) Vertical mounting

(1) Wiring cover and handling (22K or less)

1) When cable conduits are not connected Cut the protective bushes of the wiring cover with nippers or a cutter before running the cables.

Wiring cover

Protective bush

WARNING

Do not remove the protective bushes. Otherwise, the cable sheathes may be scratched by

the wiring cover edges, resulting in a short circuit or earth (ground) fault.

2) When cable conduits are connected Remove the corresponding protective bushes and connect the cable conduits.

2.2 Wiring

2.2.1 Terminal connection diagram

EC version

3-phase AC power supply

MCCB

Jumper

INSTALLATION AND WIRING

EC version

–

MCCB

3-phase AC power supply

Jumper

24VDC power output and external transistor common

(Contact input common for source logic)

Forward rotation start

Reverse rotation start

Start self-holding selection

Multi-speed selection

Second acceleration/deceleration time selection

Current input selection

Selection of automatic restart after instantaneous power failure

(Contact input common for sink logic)

Control input signals (no voltage input allowed)

Frequency setting signals (analog)

Frequency setting

potentiometer

1/2W1k

Common

Auxiliary input

Current input

High

Middle

Low

Jog mode

Output stop

Reset

R/L S/L2 T/L3

R1/L11 S1/L21

STF

STR

STOP

JOG

MRS

RES

10E(+10V)

10(+5V)

0 to 5VDC

0 to 10VDC

(Analog common)

0 to ± 5VDC

0 to ±10VDC

4 (4 to 20mADC)

PU connector

Selected

U V

P/+

(Note)

N/–

RUN

IPF

Main circuit terminal Control circuit terminal

Jumper Remove this jumper when using FR-BEL.

Jumper Remove this jumper when using FR-ABR.

Note: Terminals PR, PX are provided for

0.4K to 7.5K.

Alarm output

Running

Up to frequency

Instantaneous power failure

Overload

Frequency detection

Open collector output common Common to sink and source

Meter

(e.g. frequency meter)

Calibration resistor*

(+)AM

Analog signal output (0 to 10VDC)

(-)

Earth

(Ground)

Motor

(Ground)

Open collector outputs

Moving-coil type 1mA full-scale

Earth

When using current input for frequency setting signal, turn the AU signal on.

* Not needed when the operation panel (FR-DU04) or parameter unit (FR-PU04) is used for calibration. Used when calibration must be made near the frequency meter for such a reason as a remote frequency meter. However, the frequency meter needle may not deflect to full-scale if the calibration resistor is connected. In this case, use this resistor and the operation panel or parameter unit together to make calibration.

INSTALLATION AND WIRING

(1) Description of main circuit terminals

Symbol Terminal Name Description

1>, S<L2>,

R<L

T<L U, V, W Inverter output Connect a three-phase squirrel-cage motor.

11>,

R1<L

21>

S1<L

P/+, PR

P/+, N Brake unit connection

P/+, P1

PR, PX

AC power input

Power supply for control circuit

Brake resistor connection

Power factor improving DC reactor connection

Built-in brake circuit connection

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

Connect to the commercial power supply. Keep these terminals open when using the high power factor converter (FR-HC) and power regeneration common converter (FR-CV).

Connected to the AC power supply terminals R/L and alarm output or when using the high power factor converter (FR-HC) or power regeneration common converter (FR-CV), remove the jumpers from terminals R/L

11 and S/L2-S1/L21 and apply external power to these terminals.

L Disconnect the jumper from terminals PR-PX and connect the optional brake resistor

(FR-ABR) across terminals P/+-PR. Connect the optional FR-BU brake unit, power regeneration converter (FR-RC), high

power factor converter (FR-HC) or power regeneration common converter (FR-CV). Disconnect the jumper from terminals P/+-P1 and connect the optional power factor

improving reactor (FR-BEL). When the jumper is connected across terminals PX-PR (factory setting),

the built-in brake circuit is valid. (Provided for 7.5K or less.)

1 and S/L2. To retain the alarm display

1-R1/

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

(2) Description of control circuit terminals

Type Symbol Terminal Name Description

Turn on the STF signal to start forward rotation and turn it off to

STF Forward rotation start

STR Reverse rotation start

STOP

RH, RM, RL Multi-speed selection

JOG JOG mode selection

MRS Output stop

Input signals

RES Reset

Contacts, e.g. start (STF), stop (STOP) etc.

AU Current input selection

Start self-holding selection

Second acceleration/ deceleration time selection

Automatic restart after instantaneous power failure selection

Contact input common (sink)

24VDC power and external transistor common Contact input common (source)

stop. Acts as a programmed operation start signal in the programmed operation mode. (Turn on to start and turn off to stop.)

Turn on the STR signal to start reverse rotation and turn it off to stop.

Turn on the STOP signal to select the self-holding of the start signal.

Use the RH, RM and RL signals as appropriate to select multiple speeds.

Turn on the JOG signal to select jog operation (factory setting). Jog operation can be performed with the start signal (STF or STR).

Turn on the RT signal to select the second acceleration/ deceleration time. When the second functions such as "second torque boost" and "second V/F (base frequency)" functions have been set, these functions can also be selected by turning on the RT signal.

Turn on the MRS signal (20ms or longer) to stop the inverter output. Used to shut off the inverter output to bring the motor to a stop by the magnetic brake.

Used to reset alarm output provided when protective function is activated. Turn on the RES signal for more than 0.1s, then turn it off. Factory setting is reset always enabled. By setting Pr. 75, reset can be set to enabled only at an inverter alarm occurrence. Recover about 1s after reset is cancelled.

Only when the AU signal is turned on, the inverter can be operated with the 4-20mADC frequency setting signal. Turning on the AU signal makes the voltage input invalid.

With the CS signal on, restart can be made automatically when the power is restored after an instantaneous power failure. Note that this operation requires restart parameters to be set. When the inverter is shipped from the factory, it is set to disallow restart.

Common to the contact input terminals and terminal FM. Common output terminal for 24VDC 0.1A power (PC terminal).

When transistor output (open collector output), such as a programmable controller, is connected, connect the external power supply common for transistor output to this terminal to prevent a fault caused by undesirable current. This terminal can be used as a 24VDC, 0.1A power output. When source logic has been selected, this terminal serves as a contact input common.

When the STF and STR signals are turned on simultaneously, the stop command is given.

Input terminal function selection (Pr. 180 to Pr. 186) change terminal functions.

INSTALLATION AND WIRING

Type Symbol Terminal Name Description

Analog

Frequency setting

Contact

Open collector

Output signals

Pulse

Analog

10E

A, B, C Alarm output

RUN Inverter running

SU Up to frequency

OL Overload alarm

IPF

FU Frequency detection

FM For meter

AM Analog signal output

Frequency setting power supply

Frequency setting (voltage)

Frequency setting (current)

Auxiliary frequency setting

Frequency setting input common

Instantaneous power failure

Open collector output common

10VDC, permissible load current 10mA

5VDC, permissible load current 10mA

By entering 0 to 5VDC (0 to 10VDC), the maximum output frequency is reached at 5V (or 10V) and I/O are proportional. Switch between input 0 to 5VDC (factory setting) and 0 to 10VDC from the operation panel. Input resistance 10kΩ. Maximum permissible voltage 20V.

By entering 4 to 20mADC, the maximum output frequency is reached at 20mA and I/ O are proportional. This input signal is valid only when the AU signal is on. (Voltage input is made invalid) Input resistance approximately 250Ω. Maximum permissible current 30mA.

By entering 0 to ±5VDC or 0 to ±10VDC, this signal is added to the frequency setting signal of terminal 2 or 4. Switch between input 0 to ±5VDC and 0 to ±10VDC (factory setting) from the operation panel. Input resistance 10kΩ. Maximum permissible voltage ±20V.

Common to the frequency setting signal (terminal 2, 1 or 4) and analog output terminal AM. Do not earth (ground).

1 contact output indicating that the output has been stopped by the inverter protective function activated. 230VAC 0.3A, 30VDC 0.3A. Alarm: discontinuity across B-C (continuity across A-C), normal: continuity across B-C (discontinuity across A-C).

Switched low when the inverter output frequency is equal to or higher than the starting frequency (factory set to 0.5Hz, variable). Switched high during stop or DC injection brake operation (*2). Permissible load 24VDC 0.1A. (A voltage drop is 3.4V maximum when the signal is on.)

Switched low when the output frequency has reached within ±10% of the set frequency (factory setting, variable). Switched high during acceleration, deceleration or stop (*2). Permissible load 24VDC 0.1A.

Switched low when the stall prevention function has caused stall prevention to be activated. Switched high when stall prevention is reset (*2). Permissible load 24VDC 0.1A.

Switched low when instantaneous power failure or undervoltage protection is activated (*2). Permissible load 24VDC 0.1A.

Switched low when the output frequency has reached or exceeded the detection frequency set as appropriate. Switched high when the output frequency is below the detection frequency (*2). Permissible load 24VDC 0.1A

Common to the RUN, SU, OL, IPF and FU terminals.

One selected from 16 monitoring items, such as output frequency, is output. (*3) The output signal is proportional to the magnitude of each monitoring item.

When the frequency setting potentiometer is connected in the factory-set state, connect it to terminal 10. When it is connected to terminal 10E, change the input specifications of terminal 2.

Factory setting of output item:

Frequency permissible load current 2mA 1440 pulses/s at 60Hz

Factory setting of output item:

Frequency output signal 0 to 10VDC Permissible load current 1mA

Output terminal function selection (Pr. 190 to Pr. 195) change terminal functions.

 PU connector

RS-485

Communication

*1: Terminals PR and PX are provided for the FR-A520-0.4K to 7.5K, FR-A540-0.4K to 7.5K. *2: Low indicates that the open collector outputting transistor is on (conducts).

High indicates that the transistor is off (does not conduct).

*3: Not output while the inverter is reset.

With the operation panel connector, communication can be made through RS-485.

• Conforming standard : Standard RS-485

• Transmission format : Multi-drop link

• Communication speed : Maximum 19200 bps

• Overall length : 500m (1640.40 feet.)

INSTALLATION AND WIRING

)

2.2.2 Wiring of the main circuit

(1) Wiring instructions

1) Crimping terminals with insulation sleeves are recommended for use with the power and motor cables.

2) Cut the protective bushes of the wiring cover when running the cables. (22K or less)

3) Power must not be applied to the output terminals (U, V, W) of the inverter. Otherwise the inverter will be

damaged.

4) After wiring, wire off-cuts must not be left in the inverter.

Wire off-cuts can cause an alarm, failure or malfunction. Always keep the inverter clean. When drilling mounting holes in a control box etc., exercise care to prevent chips and other foreign matter from entering the inverter.

5) Use cables of the recommended size for wiring to make the voltage drop 2% or less.

If the wiring distance is long between the inverter and motor, a main circuit cable voltage drop will cause the motor torque to decrease especially at the output of a low frequency. (A selection example for the wiring length of 20m (65.62 feet) is shown on page 19.)

6) The overall wiring length should be 500m (1640.40 feet) maximum.

Especially for long distance wiring, the overcurrent protection may be misactivated or the devices connected to the output side may misoperate or become faulty under the influence of a charging current due to the stray capacitance of the wiring. Therefore, the maximum overall wiring length should be as indicated in the following table. (When two or more motors are connected to the inverter, the total wiring length should be within the indicated value.)

Inverter Capacity 0.4K 0.75K 1.5K or more

Non-low acoustic noise mode 300m (984.24 feet) 500m (1640.40 feet) 500m (1640.40 feet) Low acoustic noise mode 200m (656.16 feet) 300m (984.24 feet) 500m (1640.40 feet)

Overall wiring length (1.5K or more)

500m (1640.40 feet) maximum

300m

(984.24 feet)

300m

(984.24 feet)

300m (984.24 feet) + 300m (984.24 feet) = 600m (1968.48 feet

7) Connect only the recommended optional brake resistor between the terminals P and PR <+ and PR>.

These terminals must not be shorted.

8) Electromagnetic wave interference

The input/output (main circuit) of the inverter includes high frequency, which may interfere with the communication devices (such as AM radios) used near the inverter. In this case, install the FR-BIF optional radio noise filter (for use on the input side only) or FR-BSF01 or FR-BLF line noise filter to minimize interference.

INSTALLATION AND WIRING

9) Do not install a power capacitor, surge suppressor or radio noise filter (FR-BIF option) on the output side

of the inverter. This will cause the inverter to trip or the capacitor and surge suppressor to be damaged. If any of the above devices are installed, immediately remove them. (If the FR-BIF radio noise filter is connected, switching power off during motor operation may result in E.UVT. In this case, connect the radio noise filter on the primary side of the electromagnetic contactor.)

10) When rewiring after operation, make sure that the POWER lamp has gone off, and when more than 10

minutes have elapsed after power-off, check with a meter that the voltage is zero. After that, start rewiring work. For some time after power-off, there is a dangerous voltage in the capacitor.

11) Use the space on the left-hand side of the main circuit terminal block to wire the cables for connection of

the control circuit power supply terminals R1, S1 <L11, L21> of the FR-A520-11K.

R1 S1

〉〈

〈

Charge lamp

Screw size (M5)

〉

〈L1〉S〈L2〉

Connection cable

UVW

〈L

〉

〈−〉

〈+〉

CAUTION

Do not use residual current protective device as the only protection against indirect

contact.

Protective earth (ground) connection essential.

Do not connect more than 2 wires on the protective earth (ground) terminal.

Use contactor and no fuse breaker EN/IEC standard compliant.

Use transformer or surge absorber EN/IEC standard compliant.

Notes on Earthing (Grounding)

• Leakage currents flow in the inverter. To prevent an electric shock, the inverter and motor must be earthed (grounded). Earthing (grounding) must conform to the requirements of national and local safety regulations and electrical code. (JIS, NEC section 250, IEC 536 class 1 and other applicable standards)

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

• Use the thickest possible earth (ground) cable.Use the cable whose size is equal to or greater than that indicated below, and minimize the cable length. The earthing (grounding) point should be as near as possible to the inverter.

• Earth (Ground) the motor on the inverter side using one wire of the 4-core cable.

Earth (Ground)

Motor Capacity

200V class 400V class

2.2kW (3HP) or less 2 2

3.7kW (5HP) 3.5 2

5.5kW, 7.5kW (7.5HP, 10HP) 5.5 3.5 11kW to 15kW (15 to 20HP) 14 8

18.5kW to 37kW (25 to 50HP) 22 14 45kW, 55kW (60, 75HP) 38 22

(Unit: mm2)

Cable Gauge

INSTALLATION AND WIRING

)

(2) Terminal block layout

In the main circuit of the inverter, the terminals are arranged as shown below:

1) 200V class

FR-A520-0.4K, 0.75K-NA FR-A520-15K, 18.5K, 22K-NA

Jumpers

RR1ST

N/–

Jumper

UVWPR

P/+

Screw size (M4)

Jumper

Charge lamp

RR1S

Screw size (M6)

Screw size 15K (M6)

18.5K,22K (M8)

Charge lamp

FR-A520-1.5K, 2.2K, 3.7K-NA FR-A520-30K-NA

Jumpers

RR1ST

Screw size (M4)

UVW PRP1

Screw size (M4)

Jumper

N/–

P/+

Charge lamp

Jumpe

Charge lamp

RST UVW

Screw size (M6) Jumper

FR-A520-5.5K, 7.5K-NA FR-A520-37K, 45K-NA

Jumpers

RR1S

N/– P/+

P1 PR PX

UVW

Screw size (M5)

Screw size

(M4)

Charge lamp

Charge lamp Screw size (M4)

RR1S

Screw size (M8)

Jumpers

R1 S1

N/–

Jumpers

N/– P/+UVW P1

N/–

Jumper

Screw size (M4)

P1 P/+

Jumper

Jumpers

Screw size (M4)

P/+

Screw size (M8)

Screw size (M10

Screw size (M5)

Jumpers

FR-A520-11K-NA FR-A520-55K-NA

Charge lamp

RR1S

Screw size (M5)

N/– P/+P1

UVW

Jumper

Screw size (M5)

Jumpers

Screw size (M4)

Charge lamp

RR1S

Screw size (M8)

Jumpers

N/–

Screw size (M4)

P/+UVW

Jumper

Screw size (M12)

INSTALLATION AND WIRING

)

2) 400V class

FR-A540-0.4K, 0.75K, 1.5K, 2.2K, 3.7K-NA/-EC FR-A540-30K-NA/-EC

Jumpers

Screw size (M4)

UVW PR

Screw size (M4)

P1N/– P/+

Charge lamp

Jumper

Screw size (M6)

Charge lamp

UVW P1

Jumpe

Jumpers

R1 S1

N/–

Jumper

FR-A540-5.5K, 7.5K-NA/-EC FR-A540-37K, 45K, 55K-NA/-EC

Jumpers

R1 S1

><L21>

N/– P/+

Jumper

P1 PR PX

N/–

Screw size (M4)

UVW

P/+

Jumpers

11>

<L21>

Screw size (M4)

Charge lamp

<L1>

Charge lamp

SRT

Screw size (M8)

UVW P1

FR-A540-11K, 15K, 18.5K, 22K-NA/-EC

Jumpers

Screw size (M4

Charge lamp

Screw size (M4)

Screw size (M6)

P/+

Screw size (M4)

Screw size (M8)

R L

>< >< >

Screw size (M6)

UVW P1

N/– P/+

Jumper

Screw size (M6

Note: Terminal names in parenthesis are those of the EC version.

INSTALLATION AND WIRING

(3) Cables, crimping terminals, etc.

The following table lists the cables and crimping terminals used with the inputs (R, S, T) <L1, L2, L3> and outputs (U, V, W) of the inverter and the torques for tightening the screws:

•

FR-A520-0.4K to 55K-NA

Applicable Inverter

Typ e

FR-A520-0.4K to

2.2K-NA FR-A520-3.7K-NA M4 1.5 5.5-4 <4-4> 5.5-4 <2.5-4> 3.5 3.5 12 12 4 2.5 FR-A520-5.5K-NA M5 2.5 5.5-5 <6-5> 5.5-5 <4-5> 5.5 5.5 10 10 6 4 FR-A520-7.5K-NA M5 2.5 14-5 <16-5> 8-5 <6-5> 14 8 6 8 16 6 FR-A520-11K-NA M5 2.5 14-5 <16-5> 14-5 <16-5> 14 14 6 6 16 10 FR-A520-15K-NA M6 4.4 22-6 <35-6> 22-6 <16-6> 22 22 4 4 35 16 FR-A520-18.5K-NA M8 7.8 38-8 <35-8> 38-8 <25-8> 38 38 2 2 35 25 FR-A520-22K-NA M8 7.8 38-8 <70-8> 38-8 <35-8> 38 38 2 2 35 35 FR-A520-30K-NA M8 7.8 60-8 <95-8> 60-8 <30-8> 60 60 1/0 1/0 50 50 FR-A520-37K-NA M10 14.7 100-10 <95-10> 100-10 <70-10> 100 100 4/0 4/0 95 70 FR-A520-45K-NA M10 14.7 100-10 100-10 <95-10> 100 100 4/0 4/0 - FR-A520-55K-NA M12 24.5 150-12 150-12 <110-12> 150 150 MCM300 MCM300 - -

Terminal

Tightening

Screw

Torque

Size

M4 1.5 2-4 <2.5-4> 2-4 <2.5-4> 2 2 14 14 2.5 2.5

N⋅m

Crimping Terminals

R, S, T U, V, W R, S, T U , V, W R, S, T U, V, W R, S, T

HIV Cables (Note 1)

AWG mm

• FR-A540-0.4K to 55K-NA/-EC

Applicable Inverter

Typ e

FR-A540-0.4K to 3.7KNA/-EC FR-A540-5.5K-NA/-EC M4 1.5 5.5-4 <4-4> 2-4 <2.5-4> 3.5 2 12 14 4 2.5 FR-A540-7.5K-NA/-EC M4 1.5 5.5-4 <4-4> 5.5-4 <4-4> 3.5 3.5 12 12 4 4 FR-A540-11K-NA/-EC M6 4.4 5.5-6 <6-6> 5.5-6 <6-6> 5.5 5.5 10 10 6 6 FR-A540-15K-NA/-EC M6 4.4 14-6 <16-6> 8-6 <10-6> 14 8 6 8 16 10 FR-A540-18.5K-NA/-EC M6 4.4 14-6 <16-6> 8-6 <10-6> 14 8 6 8 16 10 FR-A540-22K-NA/-EC M6 4.4 22-6 <25-6> 14-6 <16-6> 22 14 4 6 25 16 FR-A540-30K-NA/-EC M6 4.4 22-6 <25-6> 22-6 <25-6> 22 22 4 4 25 25 FR-A540-37K-NA/-EC M8 7.8 38-8 <37-8> 22-8 <25-8> 38 22 2 4 35 25 FR-A540-45K-NA/-EC M8 7.8 38-8 <50-8> 38-8 <37-8> 38 38 2 2 50 35 FR-A540-55K-NA/-EC M8 7.8 60-8 <70-8> 60-8 <50-8> 60 60 1/0 1/0 50 50

Ter mi na l

Tightening

Screw

Torque

Size

M4 1.5 2-4 <2.5-4> 2-4 <2.5-4> 2 2 14 14 2.5 2.5

N⋅m

Crimping Terminals

R, S, T

1, L2, L3>

U, V, W

R, S, T

1, L2, L3>

HIV Cables (Note 1) PVC insulated Cables

U, V, W

AWG mm

R, S, T

1, L2, L3>

U, V, W

Note: 1. The cables used should be 75°C (167°F) copper cables.

2. Tighten the terminal screws to the specified torques. Undertightening can cause a short or misoperation. Overtightening can cause the screws and unit to be damaged, resulting in a short or misoperation.

PVC insulated

R, S, T

1, L2, L3>

Cables

U, V,

U, V, W

(4) Connection of the power supply and motor

Power supply

Moulded case circuit breaker

The power supply cables must be connected to R, S, T

1, L2, L3>.

If they are connected to U, V, W, the inverter will be damaged. Phase sequence need not be matched. For use with a single-phase power supply,the power supply cables must be connected to R and S <L

RST

<L1>

1 and L2>.

2><L3>

UVW

Connect the motor to U, V, W. In the above connection, turning on the forward rotation switch (signal) rotates the motor in the counterclockwise (arrow) direction when viewed from the load shaft.

Earth (Ground) terminal

Earth

(Ground)

Motor

INSTALLATION AND WIRING

(5) Connecting the control circuit to a power supply separately from the main circuit

If the magnetic contactor (MC) on the inverter power supply side is opened when the protective circuit is operated, the inverter control circuit power is lost and the alarm output signal cannot be kept on. To keep the alarm signal, terminals R1 and S1 are available. In this case, connect the power supply terminals R1 and S1 <L

11 and L21> of the control circuit to the primary side of the MC.

• Model FR-A520-0.4K to 3.7K-NA, FR-A540-0.4K to 3.7K-NA/-EC

Terminal block for main circuit

21>

11>

1) Loosen the upper screws

2) Remove the lower screws.

3) Remove the jumpers.

4) Connect the separate power supply cables for control circuit to the lower terminals (R1, S1 L

, L21).

• Model FR-A520-5.5K to 55K-NA, FR-A540-5.5K to 55K-NA/-EC

〉S1〈

〉

〈

Power supply terminal block for control circuit

〈

〉S〈

〉T〈

〉

Main power supply

Note: 1. When the main circuit power (R, S, T) <L

(terminals R1, S1 <L

11, L21>). Otherwise the inverter may be damaged.

1 L2, L3> is on, do not switch off the control power

2. When using a separate power supply, the jumpers across R-R1 and S-S1 <L must be removed. Otherwise the inverter may be damaged.

3. For a different power supply system, which takes the power of the control circuit from other than the primary side of the MC, the voltage should be equal to the main circuit voltage.

4. For the FR-A520-5.5K to 55K, FR-A540-5.5K to 55K, the power supply cables must not be connected to the lower terminals. If connected, the inverter may be damaged.

5. Supplying power to only terminals R1 <L

11> and S1 <L21> and entering the start signal will result

in an error display (E.OC1).

Power supply terminal block for control ci rcuit

1) Loosen the upper screws.

2) Remove the lower screws.

3) Pull out and remove the jumper.

4) Connect the separate power supply cables for control circuit to the upper terminals (R1, S1 〈L

〉

, L

). (Note 4)

1-L11 and L2-L21>

INSTALLATION AND WIRING

2.2.3 Wiring of the control circuit

(1) Wiring instructions

1) Terminals SD, SE and 5 are common to the I/O signals and isolated from each other. Do not earth (ground) these terminals. Avoid connecting the terminals SD and 5 and the terminals SE and 5.

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 or more parallel micro signal contacts or a twin contact to prevent a contact fault.

4) It is recommended to use the cables of 0.75mm

If the cable gauge used is 1.25mm

or more, the front cover may be lifted when there are many cables

running or the cables are run improperly, resulting in an operation panel or parameter unit contact fault.

(2) Terminal block layout

• NA version

In the control circuit of the inverter, the terminals are arranged as shown below: Terminal screw size: M3.5 Tightening torque: 1.2N

⋅m

B C PC AM 1 0E 10 2 5 4 1

RM RH RT AU STOP MRS RES SD FM

gauge for connection to the control circuit terminals.

SE RUN SU IPF OL FU SD STF STR JOG CS

•EC version

Terminal screw size: M3 Tightening torque: 1.2N

⋅m

B C SD AM 1 0E 10 2 5 4 1

SE RUN SU LPF OL STOP MRS RES PC STF

RL RM RH RT AU

STR JOG CS FM SDFU

1) For the wiring of the control circuit, strip the sheaths of the cables and use them as they are. Strip the sheath to the following dimension. A too long stripping dimension may cause a short circuit with the neighboring cable. A too short dimension may cause cable disconnection.

6mm ± 1mm

2) Loosen the terminal screw and insert the cable into the terminal.

3) Tighten the screw to the specified torque. Undertightening can cause cable disconnection or malfunction. Overtightening can cause a short circuit or malfunction due to the screw or unit damaged.

Note: Wire the stripped cable by twisting it to prevent it from becoming loose. (Do not plate the cable with

solder.)

Note: 1. Use a MCCB (Moulded case circuit breaker) or fuse on the inverter input (primary) side.

2. Make sure that the control circuit terminal wiring does not touch power circuit terminals (or screws) or conducting power circuit.

+ 227 hidden pages

Mitsubishi FR-A520-0.4K-NA, FR-A520-55K-NA, FR-A520-22K-NA, FR-A520-37K-NA, FR-A520-7.5K-NA Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual