Mitsubishi FR-A5AP User Manual


INSTRUCTION MANUAL
ORIENTATION CONTROL/PLG FEEDBACK
CONTROL/PULSE TRAIN UNIT
FR-A5AP
TYPE FR-A5AP EIBUN TORISETSU CODE 1A2H59
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Thank you for choosing the Mitsubishi transistorized inverter option unit.
C
This instruction manual gives handling information and precautions for use of this product. Incorrect handling might cause an unexpected fault. Before using the equipment, please read this manual carefully to use it to its optimum. Please forward this manual to the end user.
Safety Instructions
Do not attempt to install, operate, maintain or inspect this product until you have read through this instruction manual and appended documents carefully and can use the equipment correctly. Do not use this product until you have a full knowledge of the equipment, safety information and instructions. In this manual, the safety instruction levels are classified into "WARNING" and "CAUTION".
WARNING
AUTION
Note that even the CAUTION level may lead to a serious consequence under some circumstances. Please follow the instructions of both levels as they are important to personnel safety.
Denotes that incorrect handling may cause hazardous conditions, resulting in death or severe injury.
Denotes that incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause physical damage only.
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SAFETY INSTRUCTIONS
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 and charging part and get an electric shock.
If power is off, do not remove the front cover except for wiring or periodic inspection. You may access the
charged inverter circuits and get an electric shock.
Before starting wiring or inspection, switch power off, wait for more than 10 minutes, and check for no residual
voltage with a tester or the like.
Any person who is involved in the wiring or inspection of this equipment should be fully competent to do the
work.
Always install the option unit 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 cables to scratches, excessive stress, heavy loads or pinching. Otherwise, you may get an electric shock.
2. 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 or for some time after power-off, do not touch the inverter as it is hot and you may get burnt.
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3. Additional instructions
Also note the following points to prevent an accidental failure, injury, electric shock, etc.:
(1) Transportation and installation
CAUTION
Do not install or operate the option unit if it is damaged or has parts missing.
Do not stand or rest heavy objects on the product.
Check that the mounting orientation is correct.
Prevent screws, metal fragments, conductive bodies or oil, other flammable substance from entering the inverter.
(2) Test operation and adjustment
CAUTION
Before starting operation, confirm and adjust the parameters. A failure to do so may cause some machines to make unexpected motions.
(3) Usage
Do not modify the equipment.
WARNING
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CAUTION
When parameter clear or all parameter clear is performed, each parameter returns to the factory setting. Re-set
the required parameters before starting operation.
For prevention of damage due to static electricity, touch nearby metal before touching this product to eliminate static electricity from your body.
(4) Maintenance, inspection and parts replacement
CAUTION
Do not test the equipment with a megger (measure insulation resistance).
(5) Disposal
CAUTION
Dispose of this product as general industrial waste.
(6) General instruction
All illustrations given in this manual may have been drawn with covers or safety guards removed to provide in-depth description. Before starting operation of the product, always return the covers and guards into original positions as specified and operate the equipment in accordance with the manual.
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1 PRE-OPERATION INSTRUCTIONS 8
1.1 Unpacking and Product Confirmation 8
1.2 Packing Confirmation 8
1.3 Structure 9
2 INSTALLATION 10
2.1 Pre-Installation Instructions 10
2.2 Installation Procedure 10
2.3 Wiring 11
3 ORIENTATION CONTROL 12
3.1 Wiring Example 12
3.2 Input Circuit 13
3.3 Terminals 14
3.4 Wiring Instructions 17
3.5 Related Parameter List 20
3.6 Pre-Operation Settings 2 1
3.7 Operation 25
3.8 Instructions 32
3.9 Specifications 33
4 PLG FEEDBACK CONTROL 34
4.1 Wiring Example 34
4.2 Input Circuit 35
4.3 Terminals 36
4.4 Wiring Instructions 37
4.5 Related Parameter List 39
4.6 Pre-Operation Settings 4 0
4.7 Control Mode Setting 41
4.8 PLG Feedback Control 42
4.9 Vector control 44
4.10 Additional Functions 51
4.11 Specifications 54
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5 PULSE TRAIN INPUT 55
5.1 Wiring Example 55
5.2 Terminals 55
5.3 Adjustment 56
5.4 Parameter Definition 56
5.5 Setting Example 57
5.6 Specifications 58
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PRE-OPERATION INSTRUCTIONS

1. PRE-OPERATION INSTRUCTIONS

1.1. Unpacking and Product Confirmation

Take the option unit out of the package, check the unit name, and confirm that the product is as you ordered and intact.
Note: This product may be used with the inverter manufactured during and after February, 1998.
The inverter may be used with this unit if its SERIAL number indicated on the rating plate and package plate has the following version or later. (The SERIAL number on the package plate uses the 3 most significant digits of the following 6-digit control number and is indicated in 6 digits including the version symbol.)
Model SERIAL Number FR-A520-0.4K, 0.75K U82 FR-A520-1.5K to 11K T82 FR-A520-15K to 22K U82 FR-A520-30K to 55K K82 FR-A540-0.4K to 3.7K L82 FR-A540-5.5K, 7.5K K82 FR-A540-11K to 22K L82 FR-A540-30K to 55K D82
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







1.2. Packing Confirmation

Make sure that the package includes the following accessories:
Instruction manual 1
Mounting screws M3
Terminal resistor jumpers (Jumpers fitted to the terminal block) 3
10 2
U 8 2 Symbol Year Month Control number SERIAL number SERIAL is made up of 1 version symbol and 8 numeric characters as shown above.
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1.3. Structure

T
y
j
g
g
g
Mounting hole
erminal block
screw size M3
Front view
Mountin
holes
Rear view
Mountin
hole
Terminal s
mbol
PIN PO 5V PA2
SG PA1
FR-A5AP
Terminal resistor
PAR
PB1 PB2 PBR PC1 PC2
umpers
PCR
Option fixin
holes
Connector
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I.ISTALLATION

2.INSTALLAT ION

2.1. Pre-Installation Instructions

(1) Make sure that the input power of the inverter is off and make sure the charge light is off. (2) When the FR-A5AP unit is used for PLG feedback control or orientation control, a PLG (motor with PLG) and
external power supply are required.
When PLG feedback control and orientation control are used together, the PLG (motor with PLG) and external power
supply are shared between these controls.
(3) When the FR-A5AP unit is fitted, the programmed operation function is made invalid.
CAUTION
With input power on, do not install or remove the option unit. Otherwise, the inverter and option unit
may be damaged.

2.2. Installation Procedure

(1) Securely insert the connector of the option unit far into the connector of the inverter. At this time, also fit the option
fixing holes securely.
(2) Securely fix the option unit to the inverter on both sides with the accessory mounting screws. If the screw holes
do not match, the connector may not have been connected correctly. Check for loose connections.
CAUTION
When installing the inverter front cover, the cables to the inverter's control circuit terminals and option terminals should be routed properly in the wiring space to prevent them from being caught between the inverter and its cover.
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2.3. Wiring

y
(
)
g
(
)
Route the cables so that they do not take up a large space in the control circuit terminal block wiring area of the option unit. Wire the twisted pair shielded cable after stripping its sheath to make its cables loose. Also, protect the shield cable of the twisted pair shielded cable to ensure that it will not make contact with the conductive area. Note: During wiring, do not leave wire off-cuts in the inverter. They can cause a fault, failure or malfunction.
Accessor
2 pcs.
Option unit
screw
Inverter
Without cover
Slot 1
Slot 2
L
Shield cable
Inverter side connector
Cable routin
Option side
connector
Slot 3
Twisted pair shielded cable
Sheath Stripping Dimensions for Shield Cable
Inverter Capacity
0.4K to 3.7K L: 350mm L: 300mm L: 250mm
5.5K to 55K L: 270mm L: 220m m L: 170mm
Slot 1 Slot 2 Slot 3
I.ORIENTATION CONTROL
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3. ORIENTATION CONTROL

)
y
(
)
(
)
(
)
(
)
(
)
y
)
(
)
(
)
(
)
(
)
This function is used with a position detector (PLG) installed to the spindle of a machine tool (or the motor) to allow a rotary shaft to be stopped at the specified position (oriented). Pr. 350 "stop position command selection" is factory-set to "9999" to make the orientation control function invalid.

3.1. Wiring Example

Power suppl
NFB
R S T
Inverter
Standard motor with PLG (SF-JR
U V
W
Note 1
IM
Forward rotation Reverse rotation
Orientation command
In position Orientation fault Output common
External stop command
STF STR
Note 5
X22 SD
Note 6
ORA
Note 6
ORM
SE SD
FR-A5AX
X11 X10
X1 X0 DY
FR-A5AP
PA1 PA2 PAR
PB1 PB2 PBR PC1 PC2 PCR
5V SG
Note 7
Note 4
Note 4
Note 4
Note 1
C R
A N
B P
H K
E
5VDC
5V
0
power suppl
(Note 2
PLG
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Note:1. When the motor with a PLG used is other than the standard motor with PLG (SF-JR), the pin numbers
are different. To reduce radiated noise, connect the shield wires of the PLG cables to the CG.
2. When orientation control is used with PLG feedback control, the PLG and 5V power supply may be shared between these controls.
3. Couple the PLG in line with the motor with a speed ratio of 1 to 1 without any mechanical looseness.
4. Keep the accessory jumpers connected. However, when the same PLG is shared between the FR-A5AP and another unit (e.g. NC) which is connected with a terminal resistor, the built-in terminal resistors are
not required and should be removed. (Terminal resistors: 100)
5. Assign this function to any of the input terminals using Pr. 180 to Pr. 186 "input terminal function selection".
6. Assign this function to any of the output terminals using Pr. 190 to Pr. 195 "output terminal function selection".
7.When the stop position command is entered from outside the inverter (externally), the FR-A5AX inboard option is required.

3.2. Input Circuit

1k
+
+
+
-
-
-
1000pF
1000pF 1000pF
1000pF 1000pF
1000pF
100
100
100
100
100
100
1k
1k
1k
1k
1k
100
100
100
1F
PA1 PAR
PA2
PB1 PBR
PB2
PC1 PCR
PC2 5V
SG
Jumpers
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3.3. Terminals

SymbolTerminal Remarks Description PA1 PLG A-phase signal input terminal
PA2 PLG A-phase inverse signal input
terminal PB1 PLG B-phase signal input terminal PB2 PLG B-phase inverse signal input
terminal PC1 PLG C(Z)-phase signal input terminal
PC2 PLG C(Z)-phase inverse signal input
terminal PAR A-phase terminal resistor terminal Factory-connected with "PA2" by the
PBR B-phase terminal resistor terminal Factory-connected with "PB2" by the
PCR C(Z)-phase terminal resistor terminal Factory-connected with "PC2" by the
5V DC power (positive) input terminal SG DC power ground terminal
For information on t he pulse signals, refer to page 11.
4.75 to 6VDC (Current consumption 50mA)
A-, B- and C(Z)-phase signals are input from the PLG
jumper. Remove the jumper when the terminal resistor is not needed
jumper. Remove the jumper when the terminal resistor is not needed
jumper. Remove the jumper when the terminal resistor is not needed PLG power supply common terminals. Input PLG power. Connect the positive side to 5V and the ground side to SG. Also, connect the shield of the shield wire to SG.
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<Inverter I/O terminals>
Symbol Terminal Remarks Description
(Note 1)
X22 SD Common terminal Common terminal for the orientation
ORA
(Note 2)
ORM
(Note 2)
SE Open collector output
Note:1. Assign the function of the X22 signal to any of the input terminals using Pr. 180 to Pr. 186 "input terminal
function selection".
2. Assign the functions of the ORA/ORM signal to any of the output terminals using Pr. 190 to Pr. 195 "output terminal function selection".
Orientation command input terminal
In-position signal output terminal
Orientation fault signal output terminal
common terminal
Open collector output. Permissible load 24VDC, 0.1A Open collector output. Permissible load 24VDC, 0.1A
Used to enter an orientation signal.
signal. Switched low if the orientation has stopped within the in-position zone while the start and orientation signals are input. Switched low if the orientation has not stopped within the in-position zone while the start and orientation signals are input. Common terminal for the ORA and ORM open collector output terminals. I s olated from the common terminal of the control circuit.
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<FR-A5AX, inverter input ter mi nals>
g
Symbol Terminal Remarks Descripti on
X0 to
X11 FR­A5AX input terminal s
Inverter input terminal s
How to use terminal DY (when the stop position is specified from outside the inverter (externally) ).
DYData read timing
SD Common
PC External
Digital signal input terminals
input signal
terminal (sink) transistor
common terminal (source)
DY
Position data
Use a micro current switching contact relay for the relay contact. A transistor with the following specifications should be selected for the open collector signal: Electrical characteristics of the transistor used;
 10mA
I
C
V
Leakage current 100A max.
If I
voltage is 3V max.
Position command latch
 30V
CE
 10mA, V
C
200ms or lon
CE(sat)
er
Used to input digital signals through either relays or open collector transistors. As the command signals are ent ered, speed or position commands are selected using Pr. 360. Used when a digital signal read timing signal is necessary. Data is only read while terminals DY-SD are shorted. By opening terminals DY-SD, the data before opening is retained. Common terminal for digital signal input terminals and data read timing signals When connecting the transistor output (open collector output) of a programmable controller (PC), etc., connect the external power common (positive) to this terminal to prevent a fault occurring due to leakage current
When terminals DY-SD are open, the inverter does not import data. Therefore, if the input status of the X0-X11 signals change, the stop position data before opening of terminals DY-SD is valid. Also, the position data is imported on the leading edge of the DY signal.
Note: Pr. 300 to Pr. 304 settings for the FR-A5AX are made invalid when the stop position is set to be specified
from outside the inverter (externally), with the FR-A5AP (orientation control option) fitted to the inverter and when orientation control is used. Pr. 300 to Pr. 305 of the FR-A5AX are made valid when the stop position is not set from outside the inverter.
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3.4. Wiring Instructions

(1) Connection with the position detector (PLG).
2
Use twisted pair shielded cables (0.2mm Cables to terminals 5V and SG should be connected in parallel or be larger in size according to the cable length table as indicated below.
To protect the cables from noise, run them (at least 10cm) away from any source of noise (e.g. the main circuit and power supply voltage).
Note: If the cable size is too large to connect the terminals to the terminal block or if the number of cables is increased due to parallel connection and they cannot be contained in the wiring space, provide a junction terminal block, for example.
(2) Cable length.
1) Cable length within 30m.
or larger) to connect the FR-A5AP and position detector (PLG).
Cable Length
Within 10m At least 2 cables Within 20m At least 4 cables Within 30m At least 6 cables
Number of Parallel Cables of 0.2mm Required
2) Cable length of more than 30m.
Use a power supply slightly higher than 5V (approximately 5.5V) in addition to 6 or more parallel cables of
2
0.2mm
or cables of 1.25mm2 or more. This allows the cable length to be increased up to 100m. Note that the voltage applied across terminals 5V-SG must not exceed 6V.
2
Larger-Size Cable
0.4mm
0.75mm
1.25mm
or larger
2
or larger
2
or larger
2
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3) Connection with NC. (Or similar device)
(
)
When one position detector is shared between the FR-A5AP and NC (or another device), its output signals should be connected as shown below. In this case, the cable length between the FR-A5AP and NC should be as short as possible, within 5m.
Position detector
PLG
Inverter
FR-A5AP
NC
Max. 5m
2 parallel cables
(3) Connection of terminal resistors.
Use the jumpers across PA2-PAR, PB2-PBR and PC2-PCR to connect terminal resistors to the A, B and C(Z)­phases of the PLG. Normally, keep the jumpers fitted. However, remove the jumpers when the same PLG is shared between the FR-A5AP and the other unit (e.g. NC) which is connected with a terminal resistor.
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