Mitsubishi Electronics FR-A701 User Manual

INVERTER FR-A701

INSTRUCTION MANUAL (BASIC)

FR-A721-5.5K to 55K FR-A741-5.5K to 55K

Thank you for choosing this Mitsubishi Inverter. This Instruction Manual is intended for users who "just want to run the inverter". If you are going to utilize functions and performance, refer to the FR-A701 Series Instruction Manual (Applied) [IB0600337ENG]. The Instruction Manual (Applied) is separately available from where you purchased the inverter or your Mitsubishi sales representative.

CONTENTS

OUTLINE ....................................................................................................... 1

1.1 Product checking and parts identification .........................................................................1

1.2 Inverter and peripheral devices.........................................................................................2

1.3 Method of removal and reinstallation of the front cover....................................................4

1.4 Installation of the inverter and enclosure design ..............................................................6

WIRING........................................................................................................ 12

2.1 Terminal connection diagram......................................................................................... 12

2.2 Main circuit terminal specifications................................................................................. 13

2.3 Control circuit specifications........................................................................................... 20

2.4 Connection of motor with encoder (vector control) ........................................................ 28

PRECAUTIONS FOR USE OF THE INVERTER......................................... 35

3.1 EMC and leakage currents ............................................................................................ 35

3.2 Power-off and magnetic contactor (MC)........................................................................ 41

3.3 Inverter-driven 400V class motor ................................................................................... 42

3.4 Precautions for use of the inverter ................................................................................. 43

3.5 Failsafe of the system which uses the inverter .............................................................. 45

DRIVING THE MOTOR ............................................................................... 47

4.1 Step of operation ............................................................................................................47

4.2 Operation panel (FR-DU07)........................................................................................... 48

4.3 Before operation.............................................................................................................56

4.4 Start/stop from the operation panel (PU operation mode)............................................. 83

4.5 Start and stop using terminals (External operation)....................................................... 92

4.6 Parameter List .............................................................................................................. 100

TROUBLESHOOTING .............................................................................. 141

5.1 Reset method of protective function ............................................................................ 141

5.2 List of fault or alarm display ......................................................................................... 142

5.3 Causes and corrective actions..................................................................................... 143

5.4 Correspondences between digital and actual characters............................................ 159

5.5 Check and clear of the faults history..................................................................... 160

5.6 Check first when you have a trouble............................................................................ 162

PRECAUTIONS FOR MAINTENANCE AND INSPECTION..................... 170

6.1 Inspection item ............................................................................................................. 170

6.2 Measurement of main circuit voltages, currents and powers ...................................... 177

SPECIFICATIONS..................................................................................... 182

7.1 Rating ........................................................................................................................... 182

7.2 Common specifications ................................................................................................ 184

7.3 Outline dimension drawings......................................................................................... 185

7.4 Installation of the heatsink portion outside the enclosure for use................................ 194

701

This Instruction Manual (Basic) provides handling information and precautions for use of the equipment. Please forward this Instruction Manual (Basic) to the end user.

This section is specifically about safety matters

Do not attempt to install, operate, maintain or inspect the inverter until you have read through the Instruction Manual 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 Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".

WARNING

CAUTION

The level may even lead to a serious consequence according to conditions. Both instruction levels must be followed because these are important to personal safety.

Incorrect handling may cause hazardous conditions, resulting in death or severe injury.

Incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause only material damage.

1. Electric Shock Prevention

WARNING

z While power is ON or when the inverter is running, do not

open the front cover. Otherwise you may get an electric shock.

z Do not run the inverter with the front cover or wiring cover

removed. Otherwise you may access the exposed highvoltage terminals or the charging part of the circuitry and get an electric shock.

z Even if power is OFF, do not remove the front cover

except for wiring or periodic inspection. You may accidentally touch the charged inverter circuits and get an electric shock.

z Before wiring or inspection, power must be switched OFF.

To confirm that, LED indication of the operation panel must be checked. (It must be OFF.) Any person who is involved in wiring or inspection shall 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 (NEC section 250, IEC 536 class 1 and other applicable standards). A neutral-point earthed (grounded) power supply for 400V class inverter in compliance with EN standard must be used.

z Any person who is involved in wiring or inspection of this

equipment shall be fully competent to do the work.

z The inverter must be installed before wiring. Otherwise

you may get an electric shock or be injured.

z Setting dial and key operations must be performed with

dry hands to prevent an electric shock.

z Do not subject the cables to scratches, excessive stress,

heavy loads or pinching. Otherwise you may get an electric shock.

z Do not change the cooling fan while power is ON. It is

dangerous to change the cooling fan while power is ON.

z Do not touch the printed circuit board or handle the

cables with wet hands. Otherwise you may get an electric shock.

z When measuring the main circuit capacitor capacity, the

DC voltage is applied to the motor for 1s at powering OFF. Never touch the motor terminal, etc. right after powering OFF to prevent an electric shock.

2. Fire Prevention

CAUTION

z Inverter must be installed on a nonflammable wall without

holes (so that nobody touches the inverter heatsink on the rear side, etc.). Mounting it to or near flammable material can cause a fire.

z If the inverter has become faulty, the inverter power must

be switched OFF. A continuous flow of large current could cause a fire.

3.Injury Prevention

CAUTION

z The voltage applied to each terminal must be the ones

specified in the Instruction Manual. Otherwise burst, damage, etc. may occur.

z The cables must be connected to the correct terminals.

Otherwise burst, damage, etc. may occur.

z Polarity must be correct. Otherwise burst, damage, etc.

may occur.

z While power is ON or for some time after power-OFF, do

not touch the inverter as they will be extremely hot. Doing so can cause burns.

4. Additional Instructions

Also the following points must be noted to prevent an

accidental failure, injury, electric shock, etc.

(1) Transportation and Mounting

CAUTION

z The product must be transported in correct method that

corresponds to the weight. Failure to do so may lead to injuries.

z Do not stack the boxes containing inverters higher than

the number recommended.

z The product must be installed to the position where

withstands the weight of the product according to the information in the Instruction Manual.

z Do not install or operate the inverter if it is damaged or

has parts missing.

z When carrying the inverter, do not hold it by the front

cover or setting dial; it may fall off or fail.

z Do not stand or rest heavy objects on the product. z The inverter mounting orientation must be correct. z Foreign conductive objects must be prevented from

entering the inverter. That includes screws and metal fragments or other flammable substance such as oil.

z As the inverter is a precision instrument, do not drop or

subject it to impact.

z The inverter must be used under the following

environment. Otherwise the inverter may be damaged.

Surrounding air temperature

Ambient humidity

Storage temperature

Atmosphere

Environment

Altitude/ vibration

∗1 Temperature applicable for a short time, e.g. in transit.

-10°C to +50°C (non-freezing)

90%RH or less (non-condensing)

-20°C to +65°C *1

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

Maximum 1,000m above sea level for standard operation.

or less at 10 to 55Hz (directions of X, Y, Z

5.9m/s axes)

(2) Wiring

CAUTION

z Do not install a power factor correction capacitor or surge

suppressor/capacitor type filter on the inverter output side. These devices on the inverter output side may be overheated or burn out.

z The connection orientation of the output cables U, V, W to

the motor affects the rotation direction of the motor.

A-1

(3) Trial run

CAUTION

z Before starting operation, each parameter must be

confirmed and adjusted. A failure to do so may cause some machines to make unexpected motions.

(4) Usage

WARNING

z Any person must stay away from the equipment when the

retry function is set as it will restart suddenly after trip.

z Since pressing key may not stop output depending

on the function setting status, separate circuit and switch that make an emergency stop (power OFF, mechanical brake operation for emergency stop, etc.) must be provided.

z OFF status of the start signal must be confirmed before

resetting the inverter fault. Resetting inverter alarm with the start signal ON restarts the motor suddenly.

The inverter must be used for three-phase induction motors. Connection of any other electrical equipment to the inverter output may damage the equipment.

z Performing pre-excitation (LX signal and X13 signal)

under torque control (Real sensorless vector control) may start the motor running at a low speed even when the start command (STF or STR) is not input. The motor may also run at a low speed when the speed limit value = 0 with a start command input. It must be confirmed that the motor running will not cause any safety problem before performing pre-excitation.

z Do not modify the equipment. z

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

(5) Emergency stop

CAUTION

z A safety backup such as an emergency brake must be

provided to prevent hazardous condition to the machine and equipment in case of inverter failure.

z When the breaker on the inverter input side trips, the

wiring must be checked for fault (short circuit), and internal parts of the inverter for a damage, etc. The cause of the trip must be identified and removed before turning ON the power of the breaker.

z When any protective function is activated, appropriate

corrective action must be taken, and the inverter must be reset before resuming operation.

(6) Maintenance, inspection and parts replacement

CAUTION

z Do not carry out a megger (insulation resistance) test on

the control circuit of the inverter. It will cause a failure.

(7) Disposal

CAUTION

z The inverter must be treated as industrial waste.

General instruction

Many of the diagrams and drawings in this Instruction Manual (Basic) show the inverter without a cover or partially open for explanation. Never operate the inverter in this manner. The cover must be always reinstalled and the instruction in this Instruction Manual (Basic) must be followed when operating the inverter.

CAUTION

z The electronic thermal relay function does not guarantee

protection of the motor from overheating. It is recommended to install both an external thermal and PTC thermistor for overheat protection.

z Do not use a magnetic contactor on the inverter input for

frequent starting/stopping of the inverter. Otherwise the life of the inverter decreases.

z The effect of electromagnetic interference must be

reduced by using a noise filter or by other means. Otherwise nearby electronic equipment may be affected.

z When driving a 400V class motor by the inverter, the

motor must be an insulation-enhanced motor or measures must be taken to suppress surge voltage. Surge voltage attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor.

z When parameter clear or all parameter clear is performed,

the required parameters must be set again before starting operations because all parameters return to the initial value.

z The inverter can be easily set for high-speed operation.

Before changing its setting, the performances of the motor and machine must be fully examined.

z Stop status cannot be hold by the inverter's brake

function. In addition to the inverter’s brake function, a holding device must be installed to ensure safety.

z Before running an inverter which had been stored for a long

period, inspection and test operation must be performed.

z For prevention of damage due to static electricity, nearby

metal must be touched before touching this product to eliminate static electricity from your body.

A-2

— CONTENTS —

1OUTLINE 1

1.1 Product checking and parts identification .............................................................. 1

1.2 Inverter and peripheral devices..............................................................................2

1.2.1 Peripheral devices ..................................................................................................................... 3

1.3 Method of removal and reinstallation of the front cover......................................... 4

1.4 Installation of the inverter and enclosure design.................................................... 6

1.4.1 Inverter installation environment................................................................................................ 6

1.4.2 Cooling system types for inverter enclosure.............................................................................. 9

1.4.3 Inverter placement ................................................................................................................... 10

2WIRING 12

2.1 Terminal connection diagram...............................................................................12

2.2 Main circuit terminal specifications ...................................................................... 13

2.2.1 Specification of main circuit terminal ....................................................................................... 13

2.2.2 Terminal arrangement of the main circuit terminal, power supply and the motor wiring ......... 14

2.2.3 Cables and wiring length ......................................................................................................... 16

2.2.4 When connecting the control circuit and the main circuit separately

to the power supply ................................................................................................................. 19

2.3 Control circuit specifications ................................................................................ 20

2.3.1 Control circuit terminals ........................................................................................................... 20

2.3.2 Changing the control logic ....................................................................................................... 23

2.3.3 Control circuit terminal layout .................................................................................................. 25

2.3.4 Wiring instructions ................................................................................................................... 25

2.3.5 When connecting the operation panel using a connection cable ............................................ 26

2.3.6 RS-485 terminal block ............................................................................................................. 26

2.3.7 Communication operation........................................................................................................ 27

2.3.8 USB connector ........................................................................................................................ 27

CONTENTS

2.4 Connection of motor with encoder (vector control) .............................................. 28

3 PRECAUTIONS FOR USE OF THE INVERTER 35

3.1 EMC and leakage currents ..................................................................................35

3.1.1 Leakage currents and countermeasures ................................................................................. 35

3.1.2 EMC measures ........................................................................................................................ 37

3.1.3 Power supply harmonics ......................................................................................................... 39

3.1.4 Harmonic suppression guideline .............................................................................................39

3.2 Power-off and magnetic contactor (MC) ..............................................................41

3.3 Inverter-driven 400V class motor ......................................................................... 42

3.4 Precautions for use of the inverter ....................................................................... 43

3.5 Failsafe of the system which uses the inverter .................................................... 45

4 DRIVING THE MOTOR 47

4.1 Step of operation.................................................................................................. 47

4.2 Operation panel (FR-DU07)................................................................................. 48

4.2.1 Parts of the operation panel (FR-DU07) .................................................................................. 48

4.2.2 Basic operation (factory setting) .............................................................................................. 49

4.2.3 Operation lock (Press [MODE] for an extended time (2s)) ...................................................... 50

4.2.4 Monitoring of output current and output voltage ...................................................................... 51

4.2.5 First priority monitor ................................................................................................................. 51

4.2.6 Setting dial push ...................................................................................................................... 51

4.2.7 Changing the parameter setting value..................................................................................... 52

4.2.8 Parameter clear, all parameter clear .......................................................................................53

4.2.9 Parameter copy and parameter verification............................................................................. 54

4.3 Before operation ..................................................................................................56

4.3.1 Simple mode parameter list ..................................................................................................... 56

4.3.2 Overheat protection of the motor by the inverter (Pr. 9) .......................................................... 57

4.3.3 When the rated motor frequency is 50Hz (Pr. 3) .................................................................... 58

4.3.4 Increase the starting torque (Pr. 0) ......................................................................................... 59

4.3.5 Limit the maximum and minimum output frequency (Pr. 1, Pr. 2) ........................................... 60

4.3.6 Change acceleration and deceleration time (Pr. 7, Pr. 8)........................................................ 61

4.3.7 Selection of the start command and frequency command locations (Pr. 79) .......................... 62

4.3.8 Large starting torque and low speed torque are necessary (Advanced magnetic

flux vector control, Real sensorless vector control) (Pr. 71, Pr. 80, Pr. 81, Pr. 800) ............. 63

4.3.9 Higher accuracy operation using a motor with encoder (Vector control)

(Pr.71, Pr.80, Pr.81, Pr.359, Pr.369, Pr.800) .......................................................................... 66

4.3.10 Exhibiting the best performance of the motor performance (offline auto tuning)

(Pr. 71, Pr. 83, Pr. 84, Pr. 96) .............................................................................................. 71

4.3.11 High accuracy operation unaffected by the motor temperature

(online auto tuning) (Pr. 95) ................................................................................................ 76

4.3.12 To perform high accuracy/fast response operation (gain adjustment of Real

sensorless vector control and vector control) (Pr. 818 to Pr. 821, Pr. 880) .......................... 77

4.4 Start/stop from the operation panel (PU operation mode) ...................................83

4.4.1 Setting the set frequency to operate (example: performing operation at 30Hz) ...................... 83

4.4.2 Use the setting dial like a potentiometer to perform operation. ............................................... 85

4.4.3 Setting the frequency by switches (three-speed setting) ......................................................... 86

4.4.4 Setting the frequency by analog input (voltage input) ............................................................. 88

4.4.5 Setting the frequency by analog input (current input) .............................................................. 90

4.5 Start and stop using terminals (External operation) ............................................. 92

4.5.1 Setting the frequency by the operation panel (Pr. 79 = 3) ....................................................... 92

4.5.2 Setting the frequency by switches (three-speed setting) (Pr. 4 to Pr. 6) ................................. 94

4.5.3 Setting the frequency by analog input (voltage input) ............................................................. 96

4.5.4 Changing the frequency (60Hz, initial value) at the maximum voltage input

(5V, initial value) ...................................................................................................................... 97

4.5.5 Setting the frequency by analog input (current input) .............................................................. 98

4.5.6 Changing the frequency (60Hz, initial value) at the maximum current input

(at 20mA, initial value) ............................................................................................................. 99

4.6 Parameter List.................................................................................................... 100

4.6.1 List of parameters classified by the purpose ......................................................................... 100

4.6.2 Parameter list ........................................................................................................................ 103

5 TROUBLESHOOTING 141

5.1 Reset method of protective function .................................................................. 141

5.2 List of fault or alarm display ...............................................................................142

5.3 Causes and corrective actions...........................................................................143

5.4 Correspondences between digital and actual characters .................................. 159

5.5 Check and clear of the faults history.................................................................. 160

5.6 Check first when you have a trouble.................................................................. 162

5.6.1 Motor does not start............................................................................................................... 162

5.6.2 Motor or machine is making abnormal acoustic noise........................................................... 164

5.6.3 Inverter generates abnormal noise........................................................................................ 164

5.6.4 Motor generates heat abnormally.......................................................................................... 165

5.6.5 Motor rotates in the opposite direction .................................................................................. 165

5.6.6 Speed greatly differs from the setting .................................................................................... 165

5.6.7 Acceleration/deceleration is not smooth ................................................................................ 166

5.6.8 Motor current is too large....................................................................................................... 166

5.6.9 Speed does not accelerate .................................................................................................... 167

5.6.10 Motor and machine vibrate .................................................................................................... 167

5.6.11 Speed varies during operation............................................................................................... 168

5.6.12 Operation mode is not changed properly .............................................................................. 169

5.6.13 Operation panel (FR-DU07) display is not operating............................................................. 169

5.6.14 Power lamp is not lit .............................................................................................................. 169

5.6.15 Unable to write parameter setting.......................................................................................... 169

CONTENTS

6 PRECAUTIONS FOR MAINTENANCE AND INSPECTION 170

6.1 Inspection item...................................................................................................170

6.1.1 Daily inspection ..................................................................................................................... 170

6.1.2 Periodic inspection ................................................................................................................ 170

6.1.3 Daily and periodic inspection................................................................................................. 171

6.1.4 Display of the life of the inverter parts ................................................................................... 172

6.1.5 Checking the inverter and converter modules ....................................................................... 173

6.1.6 Cleaning ................................................................................................................................ 174

6.1.7 Replacement of parts ............................................................................................................ 174

6.2 Measurement of main circuit voltages, currents and powers............................. 177

6.2.1 Measurement of powers ........................................................................................................ 179

6.2.2 Measurement of voltages and use of PT ............................................................................... 179

6.2.3 Measurement of currents....................................................................................................... 180

6.2.4 Use of CT and transducer ..................................................................................................... 180

6.2.5 Measurement of inverter input power factor .......................................................................... 180

6.2.6 Measurement of converter output voltage (across terminals P/+ and N/-) ............................ 181

6.2.7 Measurement of inverter output frequency ............................................................................ 181

6.2.8 Insulation resistance test using megger ................................................................................ 181

6.2.9 Pressure test ......................................................................................................................... 181

III

7 SPECIFICATIONS 182

7.1 Rating................................................................................................................. 182

7.1.1 Inverter rating ........................................................................................................................ 182

7.1.2 Motor rating ........................................................................................................................... 183

7.2 Common specifications...................................................................................... 184

7.3 Outline dimension drawings...............................................................................185

7.3.1 Inverter outline dimension drawings ...................................................................................... 185

7.3.2 Dedicated motor outline dimension drawings ........................................................................ 190

7.4 Installation of the heatsink portion outside the enclosure for use ...................... 194

7.4.1 Protrusion of heatsink ............................................................................................................ 194

APPENDICES 196

Appendix 1 Main differences and compatibilities with the FR-A700 series ................. 196

Appendix 2 Instructions for compliance with the EU Directives (400V class only)..... 197

Appendix 3 Instructions for UL and cUL Compliance................................................. 199

Appendix 4 Control mode-based parameter (function) correspondence

table and instruction code list ................................................................... 201

<Abbreviations> DU: Operation panel (FR-DU07) PU: Operation panel (FR-DU07) and parameter unit (FR-PU04, FR-PU07) Inverter: Mitsubishi inverter FR-A701 series FR-A701: Mitsubishi inverter FR-A701 series Pr.: Parameter Number (Number assigned to function) PU operation: Operation using the PU (FR-DU07/FR-PU04/FR-PU07) External operation: Operation using the control circuit signals Combined operation: Combined operation using the PU (FR-DU07/FR-PU04/FR-PU07) and external operation Standard motor: SF-JR Constant-torque motor: SF-HRCA Vector dedicated motor: SF-V5RU

ONWORKS

L DeviceNet is a registered trademark of ODVA (Open DeviceNet Vender Association, Inc.). Company and product names herein are the trademarks and registered trademarks of their respective owners.

REMARKS

⋅ For differences and compatibility between the FR-A701 series and FR-A700 series, refer to page 196.

is registered trademarks of Echelon Corporation in the U.S.A. and other countries.

Product checking and parts identification

1 OUTLINE

1.1 Product checking and parts identification

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.

• Inverter Model

A721

5.5

Cooling fan

(Refer to page 175)

Symbol

A721

Front cover

(Refer to page 4)

Operation panel (FR-DU07)

Power lamp

Lit when the control circuit (R1/L11, S1/L21) is supplied with power.

Alarm lamp

Lit when the inverter is in the alarm status (major fault).

Capacity plate

Voltage Class

Three-phase 200V class

Three-phase 400V classA741

(Refer to page 48)

FR-A721-5.5K

Inverter Model

Indicate inverter capacity (kW)

Serial number

• Accessory

· Eyebolt for hanging the inverter

Capacity Eyebolt size Quantity

11K , 1 5 K M8 2

18.5K to 30K M10 2

37K to 55K M12 2

* The 5.5K and 7.5K are not provided with eyebolts.

(Refer to page 175)

USB connector

(Refer to page 337)

PU connector

(Refer to page 22)

RS-485 terminals

(Refer to page 26)

Connector for plug-in option connection

(Refer to the Instruction Manual of options.) There are three connection connectors and they are called connector 1, connector 2, and connector 3 from the top.

Voltage/current input switch

(Refer to page 12)

AU/PTC switchover switch

(Refer to Chapter 4 of the Instruction Manual (Applied).)

Control circuit terminal block

Main circuit terminal block

(Refer to page 20)

Charge lamp

Lit when power is supplied to the main circuit

Fan blockFan cover

(Refer to page 175)

(Refer to page 13)

Rating plate

Inverter Model Applied motor

Output rating Serial number

OUTLINE

(Refer to page 13)

Rating plate

FR-A721-5.5K

capacity

Input rating

REMARKS

For removal and reinstallation of covers, refer to page 4.

Harmonic suppression guideline (when inverters are used in Japan) All models of general-purpose inverters used by specific consumers are covered by "Harmonic suppression guideline for consumers

who receive high voltage or special high voltage". (For details, refer to page 39 .)

Inverter and peripheral devices

1.2 Inverter and peripheral devices

Three-phase AC power supply

Use within the permissible power supply specifications of the inverter.

(Refer to page 182)

Moulded case circuit breaker (MCCB) or earth leakage circuit breaker (ELB), fuse

The breaker must be selected carefully since an in-rush current flows in the inverter at power on.

(Refer to page 3)

Magnetic contactor (MC)

Install the magnetic contactor to ensure safety. Do not use this magnetic contactor to start and stop the inverter. Doing so will cause the inverter life to be shorten.

(Refer to page 3)

USB connector

A personal computer and an inverter can be connected with a USB (Ver1. 1) cable.

(Refer to page 27)

Inverter (FR-A701)

The life of the inverter is influenced by surrounding air temperature. The surrounding air 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 6) 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)

EMC filter (ferrite core) (FR-BLF)

Install a noise filter to reduce the electromagnetic noise generated from the inverter. Effective in the range from about 1MHz to 10MHz. When more wires are passed through, a more effective result can be obtained. The total number of wires passed through should be 4T or more.

EMC filter (capacitor) (FR-BIF)

Reduces the radio noise.

Devices connected to the output

Do not install a power factor correction capacitor, surge suppressor or radio noise filter on the output side of the inverter. When installing a moulded case circuit breaker on the output side of the inverter, contact each manufacturer for selection of the moulded case circuit breaker.

Earth (Ground)

To prevent an electric shock, always earth (ground) the motor and inverter.

: Install these options as required.

R/L1 S/L2 T/L3

Earth

(Ground)

UWV

Earth (Ground)

EMC filter (ferrite core) (FR-BLF)

Install a noise filter to reduce the electromagnetic noise generated from the inverter. Effective in the range from about 1MHz to 10MHz. A wire should be wound four turns at a maximum.

Motor

CAUTION

Do not install a power factor correction capacitor, surge suppressor or radio noise filter on the inverter output side. This will cause the inverter to trip or the capacitor, and surge suppressor to be damaged. If any of the above devices are connected, immediately remove them.

· This inverter has a built-in AC reactor (FR-HAL) and a circuit type specified in Harmonic suppression guideline in Japan is threephase bridge (capacitor smoothed) and with reactor (AC side). (Refer to page 39) Do not use an AC reactor (FR-HAL) of a standalone option except following purpose. (Note that overload protection of the converter may operate when a thyristor load is connected in the power supply system. To prevent this, always install an optional stand-alone AC reactor (FR-HAL).) A DC reactor (FR-HEL) can not be connected to the inverter.

· Electromagnetic wave interference The input/output (main circuit) of the inverter includes high frequency components, which may interfere with the communication devices (such as AM radios) used near the inverter. In this case, connecting a capacitor type filter will reduce electromagnetic wave interference.

· Refer to the instruction manual of each option and peripheral devices for details of peripheral devices.

Inverter and peripheral devices

1.2.1 Peripheral devices

Check the inverter model of the inverter you purchased. Appropriate peripheral devices must be selected according to the capacity. Refer to the following list and prepare appropriate peripheral devices:

200V class

Motor Output

(kW)

5.5 FR-A721-5.5K 40A S-N20, N21

7.5 FR-A721-7.5K 50A S-N25

11 FR-A721-11K 75A S-N35

15 FR-A721-15K 100A S-N50

18.5 FR-A721-18.5K 125A S-N50

22 FR-A721-22K 150A S-N65

30 FR-A721-30K 175A S-N80

37 FR-A721-37K 225A S-N125

45 FR-A721-45K 300A S-N150

55 FR-A721-55K 350A S-N180

400V class

Motor Output

(kW)

5.5 FR-A741-5.5K 20A S-N11, N12

7.5 FR-A741-7.5K 30A S-N20, N21

11 FR-A741-11K 40A S-N20, N21

15 FR-A741-15K 50A S-N20, N21

18.5 FR-A741-18.5K 60A S-N25

22 FR-A741-22K 75A S-N25

30 FR-A741-30K 100A S-N50

37 FR-A741-37K 125A S-N50

45 FR-A741-45K 150A S-N65

55 FR-A741-55K 175A S-N80

*1 Selections for use of the Mitsubishi 4-pole standard motor with power supply voltage of 200VAC/400VAC 50Hz. *2 Select the MCCB according to the inverter power supply capacity.

Install one MCCB per inverter. For the use in the United States or Canada, provide the appropriate UL and cUL listed Class RK5 or Class T type fuse or UL 489 molded case circuit breaker (MCCB) that is suitable for branch circuit protection.

(Refer to page 199.)

*3 Magnetic contactor is selected based on the AC-1 class. The electrical durability of magnetic contactor is 500,000 times. When the magnetic

contactor is used for emergency stop during motor driving, the electrical durability is 25 times. When using the MC for emergency stop during motor driving or using on the motor side during commercial-power supply operation, select the MC with class AC-3 rated current for the motor rated current.

Applicable Inverter Model Breaker Selection*2 Input Side Magnetic Contactor*3

MCCB INV

OUTLINE

CAUTION

· When the inverter capacity is larger than the motor capacity, select an MCCB and a magnetic contactor according to the inverter model and cable according to the motor output.

· When the breaker on the inverter input 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.

Method of removal and reinstallation of

the front cover

1.3 Method of removal and reinstallation of the front cover

•Removal of the operation panel

1) Loosen the two screws on the operation panel. (These screws cannot be removed.)

When reinstalling the operation panel, insert it straight to reinstall securely and tighten the fixed screws of the operation panel.

2) Push the left and right hooks of the operation panel and pull the operation panel toward you to remove.

•Removal of the front cover

1) Remove installation screws on the front cover 1 to remove the front cover 1.

Front cover 1

3) Pull the front cover 2 toward you to remove by pushing an installation hook on the right side using left fixed hooks as supports.

2) Loosen the installation screws of the front cover 2.

Front cover 2

Installation hook

•Reinstallation of the front cover

1) Insert the two fixed hooks on the left side of the front cover 2 into the sockets of the inverter.

3) Fix the front cover 2 with the installation screws. 4) Fix the front cover 1 with the installation

Method of removal and reinstallation of

the front cover

2) Using the fixed hooks as supports, securely press the front cover 2 against the inverter. (Although installation can be done with the operation panel mounted, make sure that a connector is securely fixed.)

Front cover 2 Front cover 2

screws.

Front cover 2

Front cover 1

REMARKS

· For the 55K, the front cover 1 is separated into two parts.

CAUTION

1. Fully make sure that the front cover has been reinstalled securely. Always tighten the installation screws of the front cover.

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 numbers to ensure that the cover removed is reinstalled to the inverter from where it was removed.

OUTLINE

Installation of the inverter and enclosure

design

1.4 Installation of the inverter and enclosure design

When an inverter enclosure is to be designed and manufactured, heat generated by contained equipment, etc., the environment of an operating place, and others must be fully considered to determine the enclosure structure, size and equipment layout. The inverter unit uses many semiconductor devices. To ensure higher reliability and long period of operation, operate the inverter in the ambient environment that completely satisfies the equipment specifications.

1.4.1 Inverter installation environment

The inverter consists of precision mechanical and electronic parts. Never install or handle it in any of the following conditions as doing so could cause an operation fault or failure.

Vibration (5.9m/s2 or more

Direct sunlight

at 10 to 55Hz (directions of X, Y, Z axes))

High temperature, high humidity

Horizontal placement

Vertical mounting (When installing two or more inverters, install them in parallel.)

Transportation by holding the front cover

Oil mist, flammable gas, corrosive gas, fluff, dust, etc.

Mounting to combustible material

As the inverter installation environment should satisfy the standard specifications indicated in the following table, operation in any place that does not meet these conditions not only deteriorates the performance and life of the inverter, but also causes a failure. Refer to the following points and take adequate measures.

Environmental standard specifications of inverter

Item Description

Surrounding air

temperature

Ambient humidity 90% RH maximum (non-condensing)

Atmosphere Free from corrosive and explosive gases, dust and dirt

Maximum Altitude 1,000m or less

Vibration

-10°C to +50°C (non-freezing)

5.9m/s

or less at 10 to 55Hz (directions of X, Y, Z axes)

Installation of the inverter and enclosure

design

(1) Temperature

The permissible surrounding air temperature of the inverter is between -10°C and +50°C. Always operate the inverter within this temperature range. Operation outside this range will considerably shorten the service lives of the semiconductors, parts, capacitors and others. Take the following measures so that the surrounding air temperature of the inverter falls within the specified range.

1) Measures against high temperature

• Use a forced ventilation system or similar cooling system. (Refer to page 9.)

• Install the enclosure in an air-conditioned electrical chamber.

• Block direct sunlight.

• Provide a shield or similar plate to avoid direct exposure to the radiated heat and wind of a heat source.

• Ventilate the area around the enclosure well.

2) Measures against low temperature

• Provide a space heater in the enclosure.

• Do not power off the inverter. (Keep the start signal of the inverter off.)

3) Sudden temperature changes

• Select an installation place where temperature does not change suddenly.

• Avoid installing the inverter near the air outlet of an air conditioner.

• If temperature changes are caused by opening/closing of a door, install the inverter away from the door.

(2) Humidity

Normally operate the inverter within the 45 to 90% range of the ambient humidity. Too high humidity will pose problems of reduced insulation and metal corrosion. On the other hand, too low humidity may produce a spatial electrical breakdown. The insulation distance specified in JEM1103 "Control Equipment Insulator" is defined as humidity 45 to 85%.

1) Measures against high humidity

• Make the enclosure enclosed, and provide it with a hygroscopic agent.

• Take dry air into the enclosure from outside.

• Provide a space heater in the enclosure.

2) Measures against low humidity What is important in fitting or inspection of the unit in this status is to discharge your body (static electricity) beforehand and keep your body from contact with the parts and patterns, besides blowing air of proper humidity into the enclosure from outside.

3) Measures against condensation Condensation may occur if frequent operation stops change the in-enclosure temperature suddenly or if the outsideair temperature changes suddenly. Condensation causes such faults as reduced insulation and corrosion.

• Take the measures against high humidity in 1).

• Do not power off the inverter. (Keep the start signal of the inverter off.)

OUTLINE

(3) Dust, dirt, oil mist

Dust and dirt will cause such faults as poor contact of contact points, reduced insulation or reduced cooling effect due to moisture absorption of accumulated dust and dirt, and in-enclosure temperature rise due to clogged filter. In the atmosphere where conductive powder floats, dust and dirt will cause such faults as malfunction, deteriorated insulation and short circuit in a short time. Since oil mist will cause similar conditions, it is necessary to take adequate measures.

Countermeasures

• Place in a totally enclosed enclosure. Take measures if the in-enclosure temperature rises. (Refer to page 9.)

• Purge air. Pump clean air from outside to make the in-enclosure pressure higher than the outside-air pressure.

Installation of the inverter and enclosure

design

(4) Corrosive gas, salt damage

If the inverter is exposed to corrosive gas or to salt near a beach, the printed board patterns and parts will corrode or the relays and switches will result in poor contact. In such places, take the measures given in Section (3).

(5) Explosive, flammable gases

As the inverter is non-explosion proof, it must be contained in an explosion proof enclosure. In places where explosion may be caused by explosive gas, dust or dirt, an enclosure cannot be used unless it structurally complies with the guidelines and has passed the specified tests. This makes the enclosure itself expensive (including the test charges). The best way is to avoid installation in such places and install the inverter in a non-hazardous place.

(6) Highland

Use the inverter at the altitude of within 1000m. If it is used at a higher place, it is likely that thin air will reduce the cooling effect and low air pressure will deteriorate dielectric strength.

(7) Vibration, impact

The vibration resistance of the inverter is up to 5.9m/s2 at 10 to 55Hz frequency (directions of X, Y, Z axes) and 1mm amplitude. Vibration or impact, if less than the specified value, applied for a long time may make the mechanism loose or cause poor contact to the connectors. Especially when impact is imposed repeatedly, caution must be taken as the part pins are likely to break.

Countermeasures

• Provide the enclosure with rubber vibration isolators.

• Strengthen the structure to prevent the enclosure from resonance.

• Install the enclosure away from sources of vibration.

Installation of the inverter and enclosure

design

1.4.2 Cooling system types for inverter enclosure

From the enclosure that contains the inverter, the heat of the inverter and other equipment (transformers, lamps, resistors, etc.) and the incoming heat such as direct sunlight must be dissipated to keep the in-enclosure temperature lower than the permissible temperatures of the in-enclosure equipment including the inverter. The cooling systems are classified as follows in terms of the cooling calculation method.

1) Cooling by natural heat dissipation from the enclosure surface (Totally enclosed type)

2) Cooling by heat sink (Aluminum heatsink, etc.)

3) Cooling by ventilation (Forced ventilation type, pipe ventilation type)

4) Cooling by heat exchanger or cooler (Heat pipe, cooler, etc.)

Cooling System Enclosure Structure Comment

Natural cooling

Forced cooling

Natural ventilation (Enclosed, open type)

Natural ventilation (Totally enclosed type)

Heatsink cooling

Forced ventilation

Heat pipe Totally enclosed type for enclosure downsizing.

Heatsink

INV

Heat pipe

INV

Low in cost and generally used, but the enclosure size increases as the inverter capacity increases. For relatively small capacities.

Being a totally enclosed type, the most appropriate for hostile environment having dust, dirt, oil mist, etc. The enclosure size increases depending on the inverter capacity.

Having restrictions on the heatsink mounting position and area, and designed for relative small capacities.

For general indoor installation. Appropriate for enclosure downsizing and cost reduction, and often used.

OUTLINE

Installation of the inverter and enclosure

design

1.4.3 Inverter placement

(1) Installation of the Inverter

Installation on the enclosure

CAUTION

⋅ When encasing multiple inverters, install them in parallel as a cooling measure. ⋅ Install the inverter vertically.

Vertical

Refer to the clearances below.

(2) Clearances around the inverter

To ensure ease of heat dissipation and maintenance, leave at least the shown clearances around the inverter. At least the following clearances are required under the inverter as a wiring space, and above the inverter as a heat dissipation space.

Surrounding air temperature and humidity

Measurement position

Inverter

5cm

Measurement position

5cm

Temperature: -10°C to 50°C Ambient humidity: 90% RH

5cm or more

10cm or more

5cm or more

10cm or more

maximum

Leave enough clearances and take cooling measures.

REMARKS

For replacing the cooling fan, 30cm of space is necessary in front of the inverter. Refer to page 175 for fan replacement.

Clearances (side)Clearances (front)

5cm

Inverter

or more

(3) Inverter mounting orientation

Mount the inverter on a wall as specified. Do not mount it horizontally or any other way.

Installation of the inverter and enclosure

design

(4) Above the inverter

Heat is blown up from inside the inverter by the small fan built in the unit. Any equipment placed above the inverter should be heat resistant.

(5) Arrangement of multiple inverters

When multiple inverters are placed in the same enclosure, generally arrange them horizontally as shown in the figure below (a). When it is inevitable to arrange them vertically to minimize space, take such measures as to provide guides since heat from the bottom inverters can increase the temperatures in the top inverters, causing inverter failures.

When mounting multiple inverters, fully take caution not to make the surrounding air temperature of the inverter higher than the permissible value by providing ventilation and increasing the enclosure size.

InverterInverterInverter Inverter

Guide Guide

Inverter

Enclosure Enclosure

(a) Horizontal arrangement (b) Vertical arrangement

Arrangement of multiple inverters

Inverter

Guide

(6) Placement of ventilation fan and inverter

Heat generated in the inverter is blown up from the bottom of the unit as warm air by the cooling fan. When installing a ventilation fan for that heat, determine the place of ventilation fan installation after fully considering an air flow. (Air passes through areas of low resistance. Make an airway and airflow plates to expose the inverter to cool air.)

Inverter Inverter

OUTLINE

Placement of ventilation fan and inverter

Terminal connection diagram

2 WIRING

2.1 Terminal connection diagram

Sink logic

Main circuit terminal

Control circuit terminal

MCCB

*6 *6

R/L1

Three-phase AC

power supply

Jumper

*1. To supply power to the

control circuit separately, remove the jumper across R1/L11 and S1/L21.

Control input signals (No voltage input allowed)

Terminal functions vary with the input terminal assignment (Pr. 178 to Pr. 189)

(Refer to Chapter 4 of the Instruction Manual (Applied))

Forward

rotation

start

Reverse

rotation

start

Start self-

holding selection

High speed

Multi-speed selection

*2. JOG terminal can be used

as pulse train input terminal. Use Pr. 291 to select JOG/pulse.

Middle

speed

Low speed

Jog operation

Second function selection

*3. AU terminal can be

used as PTC input terminal.

Terminal 4 input selection

(Current input selection)

Selection of automatic restart

Output stop

Reset

after instantaneous

power failure

Contact input common

24VDC power supply

(Common for external power supply transistor)

Frequency setting signal (Analog)

Frequency setting

potentiometer

1/2W1k

Terminal input specifications

4. can be changed by analog input specifications switchover (Pr. 73, Pr. 267). Set the voltage/current input switch in the OFF position to select voltage input (0 to 5V/0 to10V) and ON to select current input (4 to 20mA).

(Refer to Chapter 4 of the Instruction Manual (Appl ied))

Auxiliary

input

Terminal

4 input

(Current

input)

(+)

(-)

(+)

(-)

Connector for plug-in option connection

. It is recommended to use 2W1kΩ

when the frequency setting signal is changed frequently.

Earth

(Ground)

S/L2 T/L3

R1/L11 S1/L21

Main circuit

Control circuit

STF

STR

STOP

JOG

MRS

RES

PTC

10E(+10V)

10(+5V)

Option connector 1

Option connector 2

Option connector 3

SOURCE

Voltage/current

input switch

OFF

0 to 5VDC

0 to 10VDC

0 to 20mADC

(Initial value)

selectable

(Analog common)

10VDC

0 to

0 to ±5VDC

selectable

4 to 20mADC

0 to 5VDC 0 to 10VDC

selectable

SINK

(Initial value)

CAUTION

· To prevent a malfunction due to noise, keep the signal cables more than 10cm away from the power cables. Also separate the main circuit wire of the input side and the output side.

· After wiring, wire offcuts must not be left in the inverter. Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter clean. When drilling mounting holes in an enclosure etc., take care not to allow chips and other foreign matter to enter the inverter.

· Set the voltage/current input switch correctly. Different setting may cause a fault, failure or malfunction.

N/-P/+

RUN

IPF

PU connector

USB connector

TXD+

TXD-

RXD+

RXD-

Terminating

VCC

resistor

U V

*6. Do not connect any options to P/+ and

N/-.

Relay output 1 (Fault output)

Terminal functions vary with the output terminal assignment (Pr. 195, Pr. 196)

(Refer to Chapter 4 of the Instruction Manual (Applied))

Relay output 2

Open collector output

Running

Up to frequency

Instantaneous power failure

Overload

Terminal functions vary with the output terminal assignment (Pr. 190 to Pr. 194)

(Refer to Chapter 4 of the Instruction Manual (Applied))

Frequency detection

Open collector output common

/source common

Sink

7. It is not necessary when calibrating the indicator from the operation panel.

Calibration resistor *7

(+)

Analog signal output (0 to 10VDC)

(-)

RS-485 terminals

Data transmission

Data reception

GND

(Permissible load

current 100mA)

Motor

Earth (Ground)

Relay output

*8. FM terminal can be

used for pulse train output of open collector output using Pr.291.

Indicator (Frequency meter, etc.)

Moving-coil type 1mA full-scale

2.2 Main circuit terminal specifications

2.2.1 Specification of main circuit terminal

Main circuit terminal specifications

Termina l

Symbol

R/L1, S/L2, T/L3

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

R1/L11, S1/L21

P/+, N/- DC terminal Do not connect any options.

Termina l N ame Description

AC power input Connect to the commercial power supply.

Connected to the AC power supply terminals R/L1 and S/L2. To retain the fault display and fault output, remove the jumpers from terminals R/L1-R1/ L11 and S/L2-S1/L21 and apply external power to these terminals. Do not turn off the power supply for control circuit (R1/L11, S1/L21) with the

Power supply for control circuit

Earth (Ground)

main circuit power (R/L1, S/L2, T/L3) on. Doing so may damage the inverter. The circuit should be configured so that the main circuit power (R/ L1, S/L2, T/L3) is also turned off when the power supply for control circuit (R1/L11, S1/L21) is off. The following power supply capacities are required to supply power separately from R1/L11 and S1/L21: 90VA for 15K or lower, 100VA for 18.5K or higher

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

WIRING

Main circuit terminal specifications

2.2.2 Terminal arrangement of the main circuit terminal, power supply and the motor wiring

200V class

FR-A721-5.5K, 7.5K FR-A721-11K, 15K

R1/L11 S1/L21

Screw size

(M4)

Screw size (M5)

R/L1 S/L2 T/L3

N/-

Charge lamp

Jumper

Screw size (M5 for 11K, M6 for 15K)

P/+

Power supply

FR-A721-18.5K to 45K FR-A721-55K

Motor

Power supply

Screw size (M4)

R1/L11 S1/L21

Charge lamp

Jumper

Screw size

R/L1 S/L2 T/L3

(M4)

R1/L11 S1/L21

Charge lamp

Jumper

N/- P/+

Motor

Screw size (M4)

R1/L11 S1/L21

Charge lamp

Jumper

Screw size (18.5K/22K/30K: M8, 37K/45K: M10)

R/L1 S/L2

Power supply

T/L3

Motor

Screw size (M6 for 18.5K, 22K and 30K M8 for 37K and 45K)

N/-

P/+

Screw size (M12)

R/L1 S/L2 T/L3

Power supply

Motor

N/-

Screw size (M8)

P/+

400V class

FR-A741-5.5K, 7.5K FR-A741-11K, 15K

Screw size (M4)

R1/L11

S1/L21

Charge lamp

Jumper

Screw size (M4)

Main circuit terminal specifications

S1/L21

R1/L11

Screw size (M4)

Charge lamp

Jumper

P/+

R/L1 S/L2 T/L3

N/-

Power supply

FR-A741-18.5K to 45K FR-A741-55K

Screw size (M6 for 18.5K to 30K M8 for 37K and 45K)

Motor

Screw size (M4)

S1/L21

R1/L11

Charge lamp

Jumper

Screw size (M5)

R/L1 S/L2 T/L3

Power supply

Motor

S1/L21

R1/L11

P/+

N/-

Screw size (M4)

Charge lamp

Jumper

WIRING

R/L1 S/L2 T/L3

Power supply

Motor

N/-

P/+

R/L1 S/L2 T/L3

Screw size (M8)

N/-

P/+

Power supply

CAUTION

· The power supply cables must be connected to R/L1, S/L2, T/L3. (Phase sequence needs not to be matched.) Never connect the power cable to the U, V, W of the inverter. Doing so will damage the inverter.

· Connect the motor to U, V, W. At this time, turning ON the forward rotation switch (signal) rotates the motor in the counterclockwise direction when viewed from the motor shaft.

Motor

Main circuit terminal specifications

2.2.3 Cables and wiring length

(1) Applicable cable size

Select the recommended cable size to ensure that a voltage drop will be 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. The following table indicates a selection example for the wiring length of 20m.

200V class (when input power supply is 220V)

Earthing

cable

Cable Sizes

AWG/MCM *2

R/L1,

S/L2,

U, V, W

T/L3

PVC, etc. (mm2) *3

R/L1, S/L2,

T/L3

U, V, W

Earthing

cable

Applicable Inverter

Model

Terminal

Screw

Size *4

Tightening

Torque N · m

Crimping

Ter min al

R/L1, S/L2,

T/L3

U, V, W

HIV, etc. (mm2) *1

R/L1, S/L2,

T/L3

U, V, W

FR-A721-5.5K M5 2.5 5.5-5 5.5-5 5.5 5.5 5.5 10 10 6 6 6 FR-A721-7.5K M5 2.5 14-5 8-5 14 8 5.5 6 8 16 10 16 FR-A721-11K M5 2.5 14-5 14-5 14 14 14 6 6 16 16 16 FR-A721-15K M6 4.4 22-6 22-6 22 22 14 4 4 25 25 16 FR-A721-18.5K M8(M6) 7.8 38-8 38-8 38 38 22 2 2 35 35 25 FR-A721-22K M8(M6) 7.8 38-8 38-8 38 38 22 2 2 35 35 25 FR-A721-30K M8(M6) 7.8 60-8 60-8 60 60 22 1/0 1/0 50 50 25 FR-A721-37K M10(M8) 14.7 80-10 80-10 80 80 22 3/0 3/0 70 70 35 FR-A721-45K M10(M8) 14.7 100-10 100-10 100 100 38 4/0 4/0 95 95 50 FR-A721-55K M12(M8) 24.5 100-12 100-12 100 100 38 4/0 4/0 95 95 50

*1 The cable size is that of the cable (HIV cable (600V class 2 vinyl-insulated cable) etc.) with continuous maximum permissible temperature of

75°C. Assumes that the surrounding air temperature is 50°C or less and the wiring distance is 20m or less.

*2 The recommended cable size is that of the cable (THHW cable) with continuous maximum permissible temperature of 75°C. Assumes that the

surrounding air temperature is 40°C or less and the wiring distance is 20m or less. (Selection example for use mainly in the United States.)

*3 For the 15K or lower, the recommended cable size is that of the cable (PVC cable) with continuous maximum permissible temperature of 70°C.

Assumes that the surrounding air temperature is 40°C or less and the wiring distance is 20m or less. For the 18.5K or higher, the recommended cable size is that of the cable (XLPE cable) with continuous maximum permissible temperature of 90°C. Assumes that the surrounding air temperature is 40°C or less and wiring is performed in an enclosure. (Selection example for use mainly in Europe.)

*4 The terminal screw size indicates the terminal size for R/L1, S/L2, T/L3, U, V, W, and a screw for earthing (grounding).

A screw for earthing (grounding) of the 18.5K or

higher

is indicated in ( ).

400V class (when input power supply is 440V)

Earthing

Cable

Cable Sizes

AWG/MCM *2

R/L1, S/L2,

U, V, W

T/L3

PVC, etc. (mm2) *3

R/L1, S/L2,

T/L3

90°C

U, V, W

. Assumes that

Earthing

Cable

75°C

Crimping

Terminal

R/L1, S/L2,

T/L3

U, V, W

HIV, etc. (mm2) *1

R/L1, S/L2,

T/L3

U, V, W

Applicable Inverter

Model

Ter min al

Screw Size *4

Tightening

Tor q u e N·m

FR-A741-5.5K M4 1.5 2-4 2-4 2 2 3.5 12 14 2.5 2.5 4 FR-A741-7.5K M4 1.5 5.5-4 5.5-4 3.5 3.5 3.5 12 12 4 4 4 FR-A741-11K M5 2.5 5.5-5 5.5-5 5.5 5.5 8 10 10 6 6 10 FR-A741-15K M5 2.5 8-5 8-5 8 8 8 8 8 10 10 10 FR-A741-18.5K M6 4.4 14-6 8-6 14 8 14 6 8 16 10 16 FR-A741-22K M6 4.4 14-6 14-6 14 14 14 6 6 16 16 16 FR-A741-30K M6 4.4 22-6 22-6 22 22 14 4 4 25 25 16 FR-A741-37K M8 7.8 22-8 22-8 22 22 14 4 4 25 25 16 FR-A741-45K M8 7.8 38-8 38-8 38 38 22 1 2 50 50 25 FR-A741-55K M8 7.8 60-8 60-8 60 60 22 1/0 1/0 50 50 25

*1 The cable size is that of the cable (HIV cable (600V class 2 vinyl-insulated cable) etc.) with continuous maximum permissible temperature of

Assumes that the surrounding air temperature is

*2 For the 45K or lower, the recommended cable size is that of the cable (THHW cable) with continuous maximum permissible temperature of

Assumes that the surrounding air temperature is For the 55K, the recommended cable size is that of the cable (THHN cable) with continuous maximum permissible temperature of the surrounding air temperature is (Selection example for use mainly in the United States.)

*3 For the 45K or lower, the recommended cable size is that of the cable (PVC cable) with continuous maximum permissible temperature of 70°C. Assumes

that the ambient temperature is 40°C or less and the wiring distance is 20m or less. For the 55K, the recommended cable size is that of the cable (XLPE cable) with continuous maximum permissible temperature of 90°C. Assumes that the ambient temperature is 40°C or less and wiring is performed in an enclosure. (Selection example for use mainly in Europe.)

40°C

50°C

or less and the wiring distance is 20m or less.

40°C

or less and the wiring distance is 20m or less.

or less and wiring is performed in an enclosure.

The line voltage drop can be calculated by the following formula:

Main circuit terminal specifications

Line voltage drop [V]=

3 × wire resistance[mΩ/m] × wiring distance[m] × current[A]

1000

Use a larger diameter cable when the wiring distance is long or when it is desired to decrease the voltage drop (torque reduction) in the low speed range.

CAUTION

· Tighten the terminal screw to the specified torque. A screw that has been tighten too loosely can cause a short circuit or malfunction. A screw that has been tighten too tightly can cause a short circuit or malfunction due to the unit breakage.

· Use crimping terminals with insulation sleeve to wire the power supply and motor.

(2) Notes on earthing (grounding)

z Always earth (ground) the motor and inverter.

1)Purpose of earthing (grounding) Generally, an electrical apparatus has an earth (ground) terminal, which must be connected to the ground before use. An electrical circuit is usually insulated by an insulating material and encased. However, it is impossible to manufacture an insulating material that can shut off a leakage current completely, and actually, a slight current flow into the case. The purpose of earthing (grounding) the case of an electrical apparatus is to prevent operator from getting an electric shock from this leakage current when touching it. To avoid the influence of external noises, this earthing (grounding) is important to audio equipment, sensors, computers and other apparatuses that handle low-level signals or operate very fast.

2)Earthing (grounding) methods and earthing (grounding) work As described previously, earthing (grounding) is roughly classified into an electrical shock prevention type and a noise-affected malfunction prevention type. Therefore, these two types should be discriminated clearly, and the following work must be done to prevent the leakage current having the inverter's high frequency components from entering the malfunction prevention type earthing (grounding):

(a) If possible, use (l) independent earthing (grounding) in figure below for the inverter. If independent earthing

(grounding) is not available, use (ll) joint earthing (grounding) in the figure below which the inverter is connected with the other equipment at an earthing (grounding) point. The (lll) common earthing (grounding) as in the figure below, which inverter shares a common earth (ground) cable with the other equipment, must be avoided. A leakage current including many high frequency components flows in the earth (ground) cables of the inverter and inverter-driven motor. Therefore, use the independent earthing (grounding) and separated the earthing (grounding) cable of the inverter from equipments sensitive to EMI. In a high building, it may be effective to use the EMI prevention type earthing (grounding) connecting to an iron structure frame, and electric shock prevention type earthing (grounding) with the independent earthing (grounding) together.

(b) This inverter must be earthed (grounded). Earthing (Grounding) must conform to the requirements of national

and local safety regulations and electrical codes. (NEC section 250, IEC 536 class 1 and other applicable standards). Use a neutral-point earthed (grounded) power supply for 400V class inverter in compliance with EN standard.

indicated in the table on the previous page.

(d) The grounding point should be as near as possible to the inverter, and the ground wire length should be as

short as possible.

(e) Run the earth (ground) cable as far away as possible from the I/O wiring of equipment sensitive to noises and

run them in parallel in the minimum distance.

(ground) cable should be of not less than the size

WIRING

Inverter

(I) Independent earthing (grounding).......Best

Other

equipment

Inverter

(II) Joint earthing (grounding).......Good

Other

equipment

Inverter

(III) Joint earthing (grounding).......Not allowed

Other

equipment

Main circuit terminal specifications

(3) Total wiring length

The overall wiring length for the connection to a single motor or multiple motors should be within 500m (with unshielded wires). (The wiring length should be within 100m for the operation under vector control or when using shielded wires.)

Total wiring length

500m or less

300m

300m + 300m = 600m

When driving a 400V class motor by the inverter, surge voltages attributable to the wiring constants may occur at the motor terminals, deteriorating the insulation of the motor. Refer to page 42 for measures against deteriorated insulation.

CAUTION

· Especially with the long-distance wiring and the wiring with shielded wires, the inverter may be affected by a charging current caused by the stray capacitance from the wiring, leading to a malfunction of the overcurrent protective function or the fast response current limit function, or an inverter fault. It may also lead to a malfunction or fault of the equipment connected on the inverter output side. Stray capacitance from the wiring varies with its wiring conditions. The overall wiring length specified above is only a reference value. If the fast-response current limit function malfunctions, disable this function. (For Pr. 156 Stall prevention operation selection, refer

to Chapter 4 of the Instruction Manual (Applied).)

· For explanation of the surge voltage suppression filter (FR-ASF-H/FR-BMF-H) and sine wave filter (MT-BSL/BSC), refer to the manual of each option.

· Do not connect a surge voltage suppression filter (FR-ASF-H/FR-BMF-H) during the operation under vector control.

(4) Cable size of the control circuit power supply (terminal R1/L11, S1/L21)

· Terminal screw size: M4

· Cable size: 0.75mm

· Tightening torque: 1.5N·m

to 2mm

Main circuit terminal specifications

2.2.4 When connecting the control circuit and the main circuit separately to the power supply

<Connection diagram> When fault occurs, opening of the electromagnetic contactor (MC) on the

Remove the jumper

R/L1

S/L2

T/L3

R1/L11

S1/L21

Inverter

inverter power supply side results in power loss in the control circuit, disabling the fault output signal retention. Terminals R1/L11 and S1/L21 are provided to hold a fault signal. In this case, connect the power supply terminals R1/L11 and S1/L21 of the control circuit to the input side of the MC. Do not connect the power cable to incorrect terminals. Doing so may damage the inverter.

1)Remove the upper screws.

2)Remove the lower screws.

3)Pull the jumper toward you to remove. Connect the separate power supply

4) cable for the control circuit to the

upper terminals (R1/L11, S1/L21).

R1/ L11

T/L3

S/L2

R/L1

Main power supply

Power supply terminal block for the control circuit

S1/ L21

Power supply terminal block for the control circuit

FR-A721-5.5K to 15K FR-A741-5.5K to 15K

Power supply terminal block for the control circuit

R1/L11

FR-A721-18.5K to 55K FR-A741-18.5K to 55K

S1/L21

CAUTION

· Do not turn off the control power (terminals R1/L11 and S1/L21) with the main circuit power (R/L1, S/L2, T/L3) on. Doing so may damage the inverter. Make up a circuit which will switch off the main circuit power supply terminals R/L1, S/L2, T/L3 when the control circuit power supply terminals R1/L11, S1/L21 are switched off.

· Be sure to use the inverter with the jumpers across terminals R/L1 and R1/L11 and across terminals S/L2 and S1/L21 removed when supplying power from other sources. The inverter may be damaged if you do not remove the jumper.

· The voltage should be the same as that of the main control circuit when the control circuit power is supplied from other than the input side of the MC.

· When separate power is supplied from R1/L11 and S1/L21, the power capacity necessary for the 15K or lower is 90VA, for the

18.5K or higher is 100VA.

· If the main circuit power is switched OFF (for 0.1s or more) then ON again, the inverter resets and a fault output will not be held.

WIRING

Control circuit specifications

2.3 Control circuit specifications

2.3.1 Control circuit terminals

indicates that terminal functions can be selected using Pr. 178 to Pr. 196 (I/O terminal function selection) (Refer to Chapter 4 of

the Instruction Manual (Applied).)

(1) Input signals

Terminal

Symbol

Type

STF

STR

STOP

RH, RM, RL

JOG

MRS Output stop

RES Reset

Contact input

Ter minal

Name

Forward rotation start

Reverse rotation start

Start selfholding selection

Multi-speed selection

Jog mode selection

Pulse train input

Second function selection

Terminal 4 input selection

PTC input

Selection of automatic restart after instantaneous power failure

Contact input common (sink) (initial setting)

External transistor common (source)

24VDC power supply common

External transistor common (sink) (initial setting)

Contact input common (source)

24VDC power supply

Description

Turn ON the STF signal to start forward rotation and turn it OFF to stop.

Turn ON the STR signal to start reverse rotation and turn it OFF to stop.

Turn ON the STOP signal to self-hold the start signal. *2

Multi-speed can be selected according to the combination of RH, RM and RL signals.

Turn ON the JOG signal to select Jog operation (initial setting) and turn ON the start signal (STF or STR) to start Jog operation.

JOG terminal can be used as pulse train input terminal. To use as pulse train input terminal, the Pr. 291 setting needs to be changed.

(maximum input pulse: 100

Turn ON the RT signal to select second function. When the second function such as "second torque boost" and "second V/F (base frequency)" are set, turning on the RT signal selects these functions.

Turn ON the MRS signal (20ms or more) to stop the inverter output. Use to shut off the inverter output when stopping the motor by electromagnetic brake.

Used to reset fault output provided when fault occurs. Turn ON the RES signal for more than 0.1s, then turn it OFF. Initial setting is for reset always. By setting Pr. 75, reset can be set to enabled only at fault occurrence. Recover about 1s after reset is cancelled.

Terminal 4 is valid only when the AU signal is turned ON. (The frequency setting signal can be set between 4 and 20mADC.) Turning the AU signal ON makes terminal 2 (voltage input) invalid.

AU terminal is used as PTC input terminal (thermal protection of the motor). When using it as PTC input terminal, set the AU/PTC switch to PTC.

When the CS signal is left ON, the inverter restarts automatically at power restoration. Note that restart setting is necessary for this operation. In the initial setting, a restart is disabled.

(Refer to Pr. 57 Restart coasting time in Chapter 4 of Instruction Manual (Applied).)

Common terminal for contact input terminal (sink logic) and terminal FM.

When connecting the transistor output (open collector output), such as a programmable controller, when source logic is selected, connect the external power supply common for transistor output to this terminal to prevent a malfunction caused by undesirable currents.

Common output terminal for 24VDC 0.1A power supply (PC terminal).

Isolated from terminals 5 and SE.

When connecting the transistor output (open collector output), such as a programmable controller, when sink logic is selected, connect the external power supply common for transistor output to this terminal to prevent a malfunction caused by undesirable currents.

Common terminal for contact input terminal (source logic).

Can be used as 24VDC 0.1A power supply.

pulses/s)

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

the

Rated

Specifications

Input resistance

4.7kΩ Voltage at opening: 21 to 27VDC Contacts at shortcircuited: 4 to 6mADC

Input resistance 2kΩ Contacts at shortcircuited: 8 to 13mADC

Input resistance

4.7kΩ Voltage at opening: 21 to 27VDC Contacts at shortcircuited: 4 to 6mADC

--------------- ----- —

Power supply voltage range 19.2 to 28.8VDC Permissible load current 100mA

Refer to

page

141

Control circuit specifications

Terminal

Symbol

Typ e

10E

Frequency setting

*1 Set Pr. 73, Pr. 267, and a voltage/current input switch correctly, then input an analog signal in accordance with the setting.

Applying a voltage signal with voltage/current input switch ON (current input is selected) or a current signal with switch OFF (voltage input is selected) could cause component damage of the inverter or analog circuit of signal output devices.

*2 Refer to Chapter 4 of

Terminal

Name

Frequency setting power supply

Frequency setting (voltage)

Frequency setting (current)

Frequency setting auxiliary

Frequency setting common

the Instruction Manual (Applied).

Description

When connecting the frequency setting potentiometer at an initial status, connect it to terminal 10. Change the input specifications of terminal 2 when connecting it to terminal 10E. (Refer to Pr. 73 Analog input selection in Chapter 4 of

the Instruction Manual (Applied).)

Inputting 0 to 5VDC (or 0 to 10V, 0 to 20mA) provides the maximum output frequency at 5V (10V, 20mA) and makes input and output proportional. Use Pr. 73 to switch from among input 0 to 5VDC (initial setting), 0 to 10VDC, and 0 to 20mA. Set the voltage/current input switch in the ON position to select current input (0 to 20mA).

Inputting 4 to 20mADC (or 0 to 5V, 0 to 10V) provides the maximum output frequency at 20mA makes input and output proportional. This input signal is valid only when the AU signal is ON (terminal 2 input is invalid). Use Pr. 267 to switch from among input 4 to 20mA (initial setting), 0 to 5VDC, and 0 to 10VDC. Set the voltage/current input switch in the OFF position to select voltage input (0 to 5V/0 to 10V).

(Refer to Chapter 4 of the Instruction Manual (Applied).) Use Pr. 858 to switch terminal functions.

Inputting 0 to ±5 VDC or 0 to ±10VDC adds this signal to terminal 2 or 4 frequency setting signal. Use Pr. 73 to switch between the input 0 to ±5VDC and 0 to ±10VDC (initial setting). Use Pr. 868 to switch terminal functions.

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

Rated

Specifications

10VDC

Permissible load

current 10mA

5VDC

Permissible load

current 10mA Voltage input: Input resistance 10kΩ ± 1kΩ Maximum permissible voltage 20VDC Current input: Input resistance 245Ω ± 5Ω Maximum permissible current 30mA

Voltage/current input switch

switch1

switch2

Input resistance 10kΩ ± 1kΩ Maximum permissible voltage ± 20VDC

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

Refer to

page

88, 96

90, 98

(2) Output signals

Terminal

Symbol

Type

A1, B1, C1

Relay

A2, B2, C2

Terminal

Name

Relay output 1 (alarm output)

Relay output 2 1 changeover contact output *2

Description

1 changeover contact output indicates that the inverter protective function has activated and the output stopped. Fault: No conduction between B and C (conduction between A and C) Normal: Conduction between B and C (No conduction between A and C)

Rated

Specifications

Contact capacity: 230VAC 0.3A (Power factor=0.4) 30VDC 0.3A

Refer to

page

WIRING

Control circuit specifications

Terminal

Symbol

Typ e

RUN

Open collector

IPF

Pulse

Analog

Terminal

Name

Inverter running

Up to frequency

Overload warning

Instantaneous power failure

Frequency detection

Open collector output common

For meter

NPN open collector output

Analog signal output

Description

Rated

Specifications

Refer to

page

Switched low when the inverter output frequency is equal to or higher than the starting frequency (initial value 0.5Hz). Switched high during stop or DC injection brake operation.

Switched low when the output frequency reaches within the range of ±10% (initial value) of the set frequency. Switched high during acceleration/ deceleration and at a stop. *1

Switched low when stall prevention is activated by the stall prevention function. Switched high when stall prevention is cancelled.

Switched low when an instantaneous power failure and under voltage protections are activated.

Switched low when the inverter output frequency is equal to or higher than the

Alarm code (4bit) output

Permissible load 24VDC (27VDC maximum) 0.1A (A voltage drop is

2.8V maximum when the signal is on.)

*1 Low is when the

open collector output transistor is ON (conducts). High is when the transistor is OFF (does not conduct).

preset detected frequency and high when less than the preset detected frequency.

C o m m o n t e r m i n a l f o r t e r m i n a l s R U N , S U , O L , I P F, F U -------------------- -----

Permissible load current 2mA 1440pulses/s at 60Hz

Maximum output pulse: 50kpulses/s Permissible load current : 80mA

Output signal 0 to 10VDC Permissible load current 1mA (load impedance

Select one e.g. output frequency from monitor items. Not output during inverter reset. The output signal is proportional to the magnitude of the corresponding monitoring item. To set a full-scale value for monitoring the output frequency and the output current, set Pr. 56 and Pr.158.

Output item: Output frequency (initial setting)

Signals can be output from the open collector terminals by setting Pr. 291.

Output item: Output frequency (initial setting)

10kΩ or more) Resolution 8 bit

*2 Refer to Chapter 4 of the Instruction Manual (Applied).

(3) Communication

Type

RS-485

USB

Terminal

Symbol

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

TXD+

TXD-

RXD+

RXD-

RS-485 terminals

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

Terminal

Name

PU connector

Inverter transmission terminal

Inverter reception terminal

Earth (Ground)

USB connector

With the PU connector, communication can be made through RS-485. (for connection on a 1:1 basis only) . Conforming standard : EIA-485 (RS-485) . Transmission format : Multidrop link . Communication speed : 4800 to 38400bps . Overall length : 500m

With the RS-485 terminals, communication can be made through RS-485. Conforming standard : EIA-485 (RS-485) Transmission format : Multidrop link Communication speed : 300 to 38400bps Overall length : 500m

The FR Configurator can be used by connecting the inverter to the personal computer through USB. Interface:Conforms to USB1.1 Transmission speed:12Mbps Connector:USB B connector (B receptacle)

Description

Refer to

page

Control circuit specifications

2.3.2 Changing the control logic

The input signals are set to sink logic (SINK) when shipped from the factory. To change the control logic, the jumper connector on the back of the control circuit terminal block must be moved to the other position. (The output signals may be used in either the sink or source logic independently of the jumper connector position.)

1) Loosen the two installation screws in both ends of the control circuit terminal block. (These screws cannot be removed.) Pull down the terminal block from behind the control circuit terminals.

2) Change the jumper connector set to the sink logic (SINK) on the rear panel of the control circuit terminal block to source logic (SOURCE).

Jumper connector

3) Using care not to bend the pins of the inverter's control circuit connector, reinstall the control circuit terminal block and fix it with the mounting screws.

CAUTION

1. Make sure that the control circuit connector is fitted correctly.

2. While power is ON, never disconnect the control circuit terminal block.

WIRING

Control circuit specifications

4)Sink logic and source logic

⋅ In sink logic, a signal switches ON when a current flows from the corresponding signal input terminal.

Terminal SD is common to the contact input signals. Terminal SE is common to the open collector output signals.

⋅ In source logic, a signal switches ON when a current flows into the corresponding signal input terminal.

Terminal PC is common to the contact input signals. Terminal SE is common to the open collector output signals.

Current flow concerning the input/output signal when sink logic is selected

Sink logic

Current

STF

STR

Inverter

RUN

TB1

TB17

24VDC

Current flow

DC input (sink type) <Example: QX40>

Sink connector

Current flow concerning the input/output signal when source logic is selected

Source logic

Current

STF

STR

Inverter

RUN

24VDC

Current flow

DC input (source type) <Example: QX80>

TB1

TB18

Source connecto

• When using an external power supply for transistor output

⋅ Sink logic type

Use terminal PC as a common terminal, and perform wiring as shown below. (Do not connect terminal SD of the inverter with terminal 0V of the external power supply. When using terminals PC and SD as a 24VDC power supply, do not install a power supply in parallel in the outside of the inverter. Doing so may cause a malfunction due to undesirable currents.)

QY40P type transistor

output unit

Constant

voltage

circuit

TB1

TB2

TB17

TB18

24VDC

STF

STR

Inverter

24VDC (SD)

Current flow

⋅ Source logic type

Use terminal SD as a common terminal, and perform wiring as shown below. (Do not connect terminal PC of the inverter with terminal +24V of the external power supply. When using terminals PC and SD as a 24VDC power supply, do not install an external power supply in parallel with the inverter. Doing so may cause a malfunction in the inverter due to undesirable currents.)

STF

STR

24VDC

Inverter

24VDC (SD)

QY80 type transistor

output unit

Constant

voltage

circuit

Fuse

TB1

TB2

TB17

TB18

Current flow

2.3.3 Control circuit terminal layout

Terminal screw size: M3.5 Tightening torque: 1.2N·m

Control circuit specifications

A1 B1 C1 A2 B2 C2 10E 10 2 5 4

AURTRHRMRL

MRS

STOP

1AMSDRES

PCCSJOGSTRSTFSDSDFUOLIPFSURUNSE

(1) Common terminals of the control circuit (SD, 5, SE)

Terminals SD, 5, and SE are all common terminals (0V) for I/O signals and are isolated from each other. Do not earth (ground) these terminals. Avoid connecting the terminal SD and 5 and the terminal SE and 5. Terminal SD is a common terminal for the contact input terminals (STF, STR, STOP, RH, RM, RL, JOG, RT, MRS, RES, AU, CS) and frequency output signal (FM). The open collector circuit is isolated from the internal control circuit by photocoupler. Terminal 5 is a common terminal for frequency setting signal (terminal 2, 1 or 4) and analog output terminal AM. It should be protected from external noise using a shielded or twisted cable. Terminal SE is a common terminal for the open collector output terminal (RUN, SU, OL, IPF, FU). The contact input circuit is isolated from the internal control circuit by photocoupler.

(2) Signal inputs by contactless switches

The contacted input terminals of the inverter (STF, STR, STOP, RH, RM, RL, JOG, RT, MRS, RES, AU, CS) can be controlled using a transistor instead of a contacted switch as shown on the right.

STF, etc

+24V

Inverter

External signal input using transistor

2.3.4 Wiring instructions

1) It is recommended to use the cables of 0.75mm2 gauge for connection to the control circuit terminals.

If the cable gauge used is 1.25mm the cables are run improperly, resulting in an operation panel contact fault.

2) The wiring length should be 30m(200m for terminal FM) maximum.

3) Use two or more parallel micro-signal contacts or twin contacts to

prevent a contact faults when using contact inputs since the control circuit input signals are micro-currents.

4) 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).

5) Do not apply a voltage to the contact input terminals (e.g. STF) of the control circuit.

6) Always apply a voltage to the fault output terminals (A, B, C) via a relay coil, lamp, etc.

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

Micro signal contacts Twin contacts

WIRING

Control circuit specifications

2.3.5 When connecting the operation panel using a connection cable

Having an operation panel on the enclosure surface is convenient. With a connection cable, you can mount the operation panel (FR-DU07) to the enclosure surface, and connect it to the inverter.

Parameter unit connection cable (FR-CB2)(option)

Operation panel(FR-DU07)

Operation panel connection connector (FR-ADP)(option)

CAUTION

Do not connect the PU connector to the computer's LAN port, FAX modem socket or telephone connector. The inverter and machine could be damaged due to differences in electrical specifications.

REMARKS

⋅ Refer to page 4 for removal method of the operation panel.

· Overall wiring length when the operation panel is connected: 20m maximum

· Refer to the following when fabricating the cable on the user side. Commercially available product examples (as of January 2010)

Product Type Manufacturer

1) Communication cable

2) RJ-45 connector 5-554720-3 Tyco Electronics

⋅ The inverter can be connected to the computer and FR-PU04/FR-PU07.

SGLPEV-T (Cat5e/300m)

24AWG × 4P

Mitsubishi Cable Industries, Ltd.

2.3.6 RS-485 terminal block

⋅ Conforming standard: EIA-485(RS-485) ⋅ Transmission format: Multidrop link ⋅ Communication speed: MAX 38400bps ⋅ Overall length: 500m ⋅ Connection cable:Twisted pair cable

(4 pairs)

OPEN

100Ω

Terminating resistor switch

Factory-set to "OPEN". Set only the terminating resistor switch of the remotest inverter to the "100Ω" position.

TXD

RDA1

RDB1

(RXD1+)

(RXD1-)

SDA1

(TXD1+)

(TXD1-)

P5S

(VCC)SG(GND)

RDA2

(RXD2+)

SDB1

SDA2

(TXD2+)

P5S

(VCC)SG(GND)

RDB2

(RXD2-)

SDB2

(TXD2-)

RXD

VCC

2.3.7 Communication operation

Using the PU connector or RS-485 terminal, you can perform communication operation from a personal computer etc. When the PU connector is connected with a personal, FA or other computer by a communication cable, a user program can run and monitor the inverter or read and write to parameters. For the Mitsubishi inverter protocol (computer link operation), communication can be performed with the PU connector and RS-485 terminal. For the Modbus-RTU protocol, communication can be performed with the RS-485 terminal.

For further details, refer to Chapter 4 of the Instruction Manual (Applied).

Programmable controller

Inverter Inverter Inverter

2.3.8 USB connector

A personal computer and an inverter can be connected with a USB (Ver1. 1) cable. You can perform parameter setting and monitoring with the FR Configurator.

•USB communication specifications

Control circuit specifications

Multidrop link

(32 inverters maximum are connectable)

Interface

Transmission speed

Wiring length Maximum 5m

Connector

Power supply

Removal of cover

Place a flat-blade screwdriver, etc. in a slot and push up the cover to open.

Conforms to USB1.1

12Mbps

USB B connector (B receptacle)

Self-power supply

USB cable

USB connector

WIRING

Connection of motor with encoder (vector control)

2.4 Connection of motor with encoder (vector control)

Orientation control and encoder feedback control, and speed control, torque control and position control by full-scale vector control operation can be performed using a motor with encoder and a plug-in option FR-A7AP.

(1) Structure of the FR-A7AP

LED1

LED2 LED3

Mounting

hole

Terminal

block

SW1

Front view Rear view

SW2

3 2

SW3

FR-A7AP

Mounting

hole

Terminating resistor selection switch (SW2)

Switch ON/OFF of the internal terminating resistor.

(Refer to page 29.)

CON2 connector

Not used.

Encoder specification selection switch (SW1)

Used to change the specification of encoder (differential line driver/complementary).

Switch for manufacturer setting (SW3)

Do not change from initiallyset status (1, 2:OFF ).

Connector

Connect to the inverter option connector.

Terminal layout

PA2 PB2 PZ2

SD SD PO

PIN and PO are not used.

(Refer to page 29.)

(2) Terminals of the FR-A7AP

Terminal Terminal Name Description

PA1

Encoder A-phase signal input terminal

PA2 Encoder A-phase inverse signal input terminal PB1 PB2

Encoder B-phase signal input terminal

Encoder B-phase inverse signal input terminal

A-, B- and Z-phase signals are input from the encoder.

PZ1 Encoder Z-phase signal input terminal PZ2

Encoder Z-phase inversion signal input terminal

Encoder power supply (positive side) input terminal

Encoder power supply ground terminal

Not used.

Input terminal for the encoder power supply. Connect the external power supply (5V, 12V, 15V, 24V) and the encoder power cable.

Mounting

hole

PA1 PB1 PZ1

PG PG

(3) Switches of the FR-A7AP

• Encoder specification selection switch (SW1) Select either differential line driver or complementary It is initially set to the differential line driver. Switch its position according to output circuit.

Connection of motor with encoder (vector control)

SW2

Differential line driver (initial status)

Complementary

SW3

FR-A7AP

SW1

• Terminating resistor selection switch (SW2) Select ON/OFF of the internal terminating resistor. Set the switch to ON (initial status) when an encoder output type is differential line driver and

Internal terminating resistor-ON (initial status)

SW2

SW3

set to OFF when complementary. ON : with internal terminating resistor (initial status)

SW1

OFF : without internal terminating resistor

REMARKS

· Set all switches to the same setting (ON/OFF).

· If the encoder output type is differential line driver, set the terminating resistor switch to the "OFF" position when sharing the same encoder with other unit (NC (numerical controller), etc.) or a terminating resistor is connected to other unit.

Internal terminating resistor-OFF

• Motor used and switch setting

Motor

Mitsubishi standard motor with encoder Mitsubishi high efficiency motor with encoder

Mitsubishi constant-torque motor with encoder

SF-JR Differential ON 5V

SF-HR Differential ON 5V

Others

SF-JRCA Differential ON 5V

SF-HRCA Differential ON 5V

Others

Encoder Specification

Selection Switch (SW1)

*1 *1 *1

Vector control dedicated motor SF-V5RU Complimentary OFF 12V

Other manufacturer motor with encoder –

*1 *1 *1

*1 Set according to the motor (encoder) used. *2 Choose a power supply (5V/12V/15V/24V) for encoder according to the encoder used.

Terminating Resistor

Selection Switch (SW2)

Power

Specifications

FR-A7AP

CAUTION

SW3 switch is for manufacturer setting. Do not change the setting.

• Encoder specification

Item Encoder for SF-JR/HR/JRCA/HRCA Encoder for SF-V5RU

Resolution 1024 Pulse/Rev 2048 Pulse/Rev

Power supply voltage

Current consumption

Output signal form

5VDC±10% 12VDC±10%

150mA 150mA

A, B phases (90° phase shift) Z phase: 1 pulse/rev

Output circuit Differential line driver 74LS113 equivalent Complimentary

Output voltage

H level: 2.4V or more L level: 0.5V or less

H level: "Power supply for encoder-3V" or more L level: 3V or less

CAUTION

Encoder with resolution of 1000 to 4096 pulse/rev is recommended.

WIRING

Connection of motor with encoder (vector control)

ithout i

(4) Encoder Cable

SF-JR/HR/JRCA/HRCA Motor with Encoder SF-V5RU, SF-THY

Earth cable

60mm

FR-A701

(FR-A7AP)

PA1 PA2 PB1 PB2 PZ1 PZ2

PG SD

F-DPEVSB 12P 0.2mm

Approx. 140mm

Type Length L (m)

FR-JCBL5 5 FR-JCBL15 15 FR-JCBL30 30

Encoder

C R A N B P

H K

2mm

MS3057-12A

MS3106B20-29S

Positioning keyway

MS3106B20-29S

(As viewed from wiring side)

Inverter side

Earth cable

60mm

⋅ A P clip for earthing (grounding) a

shielded cable is provided.

FR-A701

(FR-A7AP)

F-DPEVSB 12P 0.2mm

11m m

PA1 PA2 PB1 PB2

PZ1 PZ2

2mm

Encoder side connector

Type Length L (m)

FR-V7CBL5 5 FR-V7CBL15 15 FR-V7CBL30 30

Encoder

A B C D F G

S R

MS3057-12A

MS3106B20-29S

Positioning keyway

(As viewed from wiring side)

MS3106B20-29S

* As the terminal block of FR-A7AP is an insertion type, earthing cables need to be modified. (See below)

• When using the dedicated encoder cable (FR-JCBL, FR-V5CBL, etc.) for the conventional motor, cut the crimpling terminal of the encoder cable and strip its sheath to make its cables loose. Also, protect the shielded cable of the twisted pair

Wire stripping size

shielded cable to ensure that it will not make contact with the conductive area. Wire the stripped wire after twisting it to prevent it from becoming loose. In addition, do not solder it.

5mm

Use a blade terminal as necessary.

REMARKS

Information on blade terminals

Commercially available product examples (as of January 2010)

zPhoenix Contact Co.,Ltd.

Terminal Screw

Size

Wire Size (mm2)

with insulation sleeve without insulation sleeve

M2 0.3, 0.5 AI 0,5-6WH A 0,5-6

Blade Terminal Model

Blade terminal

crimping tool

CRIMPFOX 6

zNICHIFU Co.,Ltd.

Terminal Screw

Size

Wire Size (mm2)

0.3 to 0.75 BT 0.75-7 VC 0.75 NH 67

en using the blade terminal (w

Blade terminal product

number

nsulation sleeve),

Insulation product

number

Blade terminal

crimping tool

use care so that the twisted wires do not come out.

Connection of motor with encoder (vector control)

Connection terminal compatibility table

Motor SF-V5RU, SF-THY SF-JR/HR/JRCA/HRCA (with Encoder)

Encoder cable FR-V7CBL FR-JCBL

PA1 PA PA

PA2 Keep this open. PAR

PB1 PB PB

FR-A7AP terminal

(5) Wiring

• Speed control

Standard motor with encoder (SF-JR), 5V differential line driver

PB2 Keep this open. PBR

PZ1 PZ PZ

PZ2 Keep this open. PZR

PG PG 5E

SD SD AG2

Vector control dedicated motor

(SF-V5RU, SF-THY), 12V complementary

Three-phase AC power supply

Forward rotation start Reverse rotation start

Contact input common

Frequency command

Frequency setting

potentiometer

1/2W1k

Torque limit

command

( 10V)

(+) (-)

• Torque control

Standard motor with encoder (SF-JR), 5V differential line driver

Three-phase AC power supply

Forward rotation start

Reverse rotation start

Contact input common

Speed limit command

Frequency setting

potentiometer

1/2W1k

Torque command

( 10V)

SF-JR motor

MCCB

R/L1 S/L2 T/L3

Inverter

with encoder U V

Three-phase

AC power

STF

FR-A7AP

STR

PA1

PA2

PB1

PB2

Differential

PZ1

PZ2

Complementary

Terminating resistor ON

OFF

Earth (Ground)

5VDC power supply *5

(-)

(+)

Encoder

supply

MCCB MC

Inverter

External thermal relay input

FR-A7AP

Differential

Complementary

Terminating

resistor

OFF

CS(OH)

PA1

PA2

PB1

PB2

PZ1

PZ2

2W1kΩ

SF-V5RU, SF-THY

OCR

A B C

U V

Earth

Thermal relay

(Ground)

protector

G1 G2

12VDC power supply *5

(-)

(+)

FAN

Encoder

Vector control dedicated motor

(SF-V5RU, SF-THY),

WIRING

12V complementary

(+) (-)

MCCB

R/L1 S/L2 T/L3

Inverter

U V

SF-JR motor

with encoder

U V

Three-phase

AC power

STF

FR-A7AP

STR

PA1

PA2

PB1

PB2

Differential

PZ1

PZ2

Complementary

Terminating

resistor ON

OFF

Earth (Ground)

(+)

5VDC

(-)

power supply

Encoder

supply

MCCB MC

Inverter

External thermal relay input

FR-A7AP

Differential

Complementary

Terminating

resistor

OFF

CS(OH)

PA1

PA2

PB1

PB2

PZ1

PZ2

U V

2W1kΩ

SF-V5RU, SF-THY

OCR

A B C

U V

Earth

Thermal relay

(Ground)

protector

G1 G2

12VDC power supply *5

(-)

(+)

FAN

Encoder

Connection of motor with encoder (vector control)

• Position control

Vector control dedicated motor (SF-V5RU, SF-THY), 12V complementary

Positioning unit

MELSEQ-Q QD75P1

FLS

RLS

DOG

STOP

CLEAR

PULSE F

PULSE R

CLEAR COM

PULSE COM

RDY COM

COM

READY

Torque limit command

(

10V)

Three-phase AC

power supply

Forward stroke end

Reverse stroke end

Pre-excitation/servo on

Clear signal

Pulse train

Sign signal

24VDC power supply

Preparation ready signal

(+) (-)

power supply

MCCB

MCCB MC

R/L1

Inverter

S/L2 T/L3

External thermal relay input

STF

FR-A7AP

STR

LX *

CLR

JOG

*10

Differential

NP *

line driver

Complementary

Terminating

resistor

RDY

*11

OFF

CS(OH)

*4 *6

PA1

PA2

PB1

PB2

PZ1

PZ2

U V

2W1kΩ

SF-V5RU, SF-THY

OCR

A B C

U V

Earth (ground)

12VDC

(-)

(+)

power supply

Thermal protector

FAN

Encoder

*1 The pin number differs according to the encoder used.

Speed control, torque control, and position control by pulse train input are properly performed without the connection of

the Z-phase. *2 Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio should be 1:1. *3 Earth (Ground) the shielded cable of the encoder cable to the enclosure with a P clip, etc. (Refer to page 33.) *4 For the complementary, set the terminating resistor selection switch to off position. (Refer to page 29.) *5 A separate power supply of 5V/12V/15V/24V is necessary according to the encoder power specification. *6 For terminal compatibility of the FR-JCBL, FR-V7CBL and FR-A7AP, refer to page 31. *7 For the fan of the 7.5kW or less dedicated motor, the power supply is single phase. (200V/50Hz, 200 to 230V/60Hz) *8 Assign OH (external thermal input) signal to the terminal CS. (Set "7" in Pr. 186 )

Connect a 2W1kΩ resistor between the terminal PC and CS (OH). Install the

resistor pushing against the bottom part of the terminal block so as to avoid a

contact with other cables.

CS(OH)

Control circuit terminal block

Refer to Chapter 4 of the Instruction Manual (Applied) for details of Pr. 186 CS

terminal function selection. *9 Assign the function using Pr. 178 to Pr. 184, Pr. 187 to Pr. 189 (input terminal function

selection).

Resistor (2W1kΩ)

*10 When position control is selected, terminal JOG function is invalid and the simple position pulse train input terminal

becomes valid. *11 Assign the function using Pr. 190 to Pr. 194 (output terminal function selection).

Connection of motor with encoder (vector control)

(6) Instructions for encoder cable wiring

• Use twisted pair shield cables (0.2mm2 or larger) to connect the FR-A7AP and position detector. Cables to terminals PG and SD should be connected in parallel or be larger in size according to the cable length. To protect the cables from noise, run them away from any source of noise (e.g. the main circuit and power supply voltage).

Wiring Length Parallel Connection Larger-Size Cable

Within 10m At least two cables in parallel

Within 20m At least four cables in parallel

Cable gauge

0.2mm

Within 100m * At least six cables in parallel

* When differential line driver is set and a wiring length is 30m or more

The wiring length can be extended to 100m by slightly increasing the power by 5V (approx. 5.5V) using six or more cables with gauge size of 0.2mm in parallel or a cable with gauge size of 1.25mm2 or more. Note that the voltage applied should be within power supply specifications of encoder.

• To reduce noise of the encoder cable, earth (ground) the encoder shielded cable to the enclosure (as near as the inverter) with a P clip or U clip made of metal.

REMARKS

· For details of the optional encoder dedicated cable (FR-JCBL/FR-V7CBL), refer to page 30.

· The FR-V7CBL is provided with a P clip for earthing (grounding) shielded cable.

(7) Parameter for encoder (Pr. 359, Pr. 369)

Parameter

Number

Name

Initial Value

Setting

Range

0.4mm2 or larger

0.75mm

1.25mm

Earthing (grounding) example using a P clip

or larger

Encoder cable

Shield

P clip

Description

359

Encoder rotation direction

369

Number of encoder pulses

1024 0 to 4096

The above parameters can be set when the FR-A7AP (option) is mounted.

(8) Motor for vector control and parameter setting

Pr. 9

Motor Name

Mitsubishi standard motor

Mitsubishi constanttorque motor

Mitsubishi vector control dedicated motor

Other manufacturer's standard motor

SF-JR SF-HR Others SF-JRCA 4P SF-HRCA Others SF-V5RU

(1500r/min series)

SF-V5RU

(except for 1500r/ min series)

SF-THY 0

—

Electronic thermal

O/L relay

Motor rated current

0 *3 30 Motor capacity 4 1 2048

0 *3 13 *1 Motor capacity 4 1 2048

*3 33 *1 Motor capacity 4 1 2048

Motor rated current

Other manufacturer's constant-torque

—

Motor rated current

motor Values in the bolded frame are initial values.

*1 Offline auto tuning is necessary. (Refer to page 71) *2 Set this parameter according to the motor (encoder) used. *3 Use thermal protector input provided with the motor.

Pr. 71

Applied motor

Motor capacity

0 Motor capacity

40 Motor capacity

3 *1 Motor capacity

1 Motor capacity 4 1 1024

50 Motor capacity

13 *1 Motor capacity

3 *1 Motor capacity

13 *1 Motor capacity

Encoder

CCW

Encoder

Forward rotation is clockwise rotation when viewed from A.

Forward rotation is counterclockwis rotation when viewed from A.

Set the number of encoder pulses output. Set the number of pulses before it is multiplied by 4.

Pr. 80

Pr. 81

Number of motor

poles

Number of motor poles

Pr. 359

Encoder rotation

direction

1 1024 1 1024

*2 *2

1 1024

*2 *2

Pr. 369

Number of

encoder pulses

WIRING

♦Parameters referred to♦

• Vector control (speed control, torque control, position control), orientation control, encoder feedback control

Refer to Chapter 4 of the Instruction Manual (Applied).

Connection of motor with encoder (vector control)

(9) Combination with a vector control dedicated motor

Refer to the table below when using with a vector control dedicated motor.

• Combination with the SF-V5RU

Vol ta ge 200V class 400V class

Rated speed

Base frequency 50Hz

Maximum speed

Motor capacity

3.7kW 112M SF-V5RU3K FR-A721-5.5K — — —

5.5kW 132S SF-V5RU5K FR-A721-7.5K 132S SF-V5RUH5K FR-A741-7.5K

7.5kW 132M SF-V5RU7K FR-A721-11K 132M SF-V5RUH7K FR-A741-11K

11kW 160M SF-V5RU11K FR-A721-15K 160M SF-V5RUH11K FR-A741-15K

15kW 160L SF-V5RU15K FR-A721-18.5K 160L SF-V5RUH15K FR-A741-18.5K

18.5kW 180M SF-V5RU18K FR-A721-22K 180M SF-V5RUH18K FR-A741-22K

22kW 180M SF-V5RU22K FR-A721-30K 180M SF-V5RUH22K FR-A741-30K

30kW 200L

37kW 200L

45kW 200L *2 SF-V5RU45K FR-A721-55K 200L *2 SF-V5RUH45K FR-A741-55K

Motor frame

number

*2 SF-V5RU30K FR-A721-37K 200L *2 SF-V5RUH30K FR-A741-37K

*2 SF-V5RU37K FR-A721-45K 200L *2 SF-V5RUH37K FR-A741-45K

Motor model Inverter model

• Combination with the SF-V5RU1, 3, 4 and SF-THY

SF-V5RU1 (1:2) SF-V5RU3 (1:3) SF-V5RU4 (1:4)

Vol ta ge 200V class

Rated speed

Base

frequency

Maximum

speed

Motor

capacity

3.7kW 132S SF-V5RU3K1 FR-A721-5.5K 132M SF-V5RU3K3 FR-A721-5.5K 160L SF-V5RU3K4 FR-A721-7.5K

5.5kW 132M SF-V5RU5K1 FR-A721-7.5K 160M SF-V5RU5K3 FR-A721-7.5K 180L SF-V5RU5K4 FR-A721-7.5K

7.5kW 160M SF-V5RU7K1 FR-A721-11K 160L SF-V5RU7K3 FR-A721-11K 200L SF-V5RU7K4 FR-A721-11K

11k W 160L

15kW 180M

18.5kW 180L

22kW 200L

30kW 200L*3

37kW 225S

45kW

Models surrounded by black borders and 400V class are developed upon receipt of order.

Motor frame

number

250MD

*1 The maximum speed is 2400r/min. *2 80% output in the high-speed range. (The output is reduced when the speed is 2400r/min or more.) *3 90% output in the high-speed range. (The output is reduced when the speed is 1000r/min or more.)

1000r/min 1000r/min 500r/min

33.33Hz 33.33Hz 16.6Hz

2000r/min 3000r/min 2000r/min

Motor

model

SF-V5RU11K1

SF-V5RU15K1

SF-V5RU18K1

SF-V5RU22K1

SF-V5RU30K1

SF-V5RU37K1

SF-THY FR-A721-55K

Inverter

model

FR-A721-15K 180M

FR-A721

FR-A721-22K 200L

FR-A721-30K 200L

FR-A721-37K 225S*1

FR-A721-45K

-18.5K

Motor frame

number

180L

250MD

*1 SF-THY FR-A721-45K

250MD

*1 SF-THY FR-A721-55K

1500r/min

3000r/min

Motor

model

SF-V5RU11K3

SF-V5RU15K3

SF-V5RU18K3

SF-V5RU22K3

SF-V5RU30K3

Motor frame

number

Inverter

model

FR-A721-15K 225S

FR-A721

-18.5K

FR-A721-22K

FR-A721-30K

FR-A721-37K

Motor model Inverter model

Motor frame

number

225S

250MD

280MD

Motor

Inverter

model

SF-V5RU11K4

SF-V5RU15K4

SF-THY FR-A721-22K

SF-THY FR-A721-30K

SF-THY FR-A721-37K

SF-THY FR-A721-45K

SF-THY FR-A721-55K

FR-A721-15K

FR-A721-22K

model

EMC and leakage currents

3 PRECAUTIONS FOR USE OF THE INVERTER

3.1 EMC and leakage currents

3.1.1 Leakage currents and countermeasures

Capacitances exist between the inverter I/O cables, other cables and earth and in the motor, through which a leakage current flows. Since its value depends on the static capacitances, carrier frequency, etc., low acoustic noise operation at the increased carrier frequency of the inverter will increase the leakage current. Therefore, take the following measures. Select the earth leakage circuit breaker according to its rated sensitivity current, independently of the carrier frequency setting.

(1) To-earth (ground) leakage currents

Leakage currents may flow not only into the inverter's own line but also into the other lines through the earth (ground) cable, etc. These leakage currents may operate earth (ground) leakage circuit breakers and earth leakage relays unnecessarily.

z Suppression technique

⋅ If the carrier frequency setting is high, decrease the Pr. 72 PWM frequency selection setting. Note that motor noise

increases. Selecting Pr. 240 Soft-PWM operation selection makes the sound inoffensive.

⋅ By using earth leakage circuit breakers designed for harmonic and surge suppression in the inverter's own line and

other line, operation can be performed with the carrier frequency kept high (with low noise).

z To-earth (ground) leakage currents

⋅ Take caution as long wiring will increase the leakage current. Decreasing the carrier frequency of the inverter

reduces the leakage current.

⋅ Increasing the motor capacity increases the leakage current. The leakage current of the 400V class is larger than

that of the 200V class.

(2) Line-to-line leakage currents

Harmonics of leakage currents flowing in static capacitances between the inverter output cables may operate the external thermal relay unnecessarily. When the wiring length is long (50m or more) for the 400V class small-capacity model (7.5K or lower), the external thermal relay is likely to operate unnecessarily because the ratio of the leakage current to the rated motor current increases.

z Line-to-line leakage current data example (200V class)

Motor Capacity

(kW)

3.7 12.8 440 630

5.5 19.4 490 680

7.5 25.6 535 725

Rated Motor

Current(A)

Wiring length 50m Wiring length 100m

Leakage Currents(mA)

⋅Motor SF-JR 4P ⋅Carrier frequency: 14.5kHz

⋅Used wire: 2mm

Cabtyre cable

, 4cores

*The leakage currents of the 400V class are about twice as large.

MCCB MC

Power supply

z Measures

⋅ Use Pr. 9 Electronic thermal O/L relay. ⋅ If the carrier frequency setting is high, decrease the Pr. 72 PWM frequency selection setting. Note that motor noise

increases. Selecting Pr. 240 Soft-PWM operation selection makes the sound inoffensive. To ensure that the motor is protected against line-to-line leakage currents, it is recommended to use a temperature sensor to directly detect motor temperature.

z Installation and selection of moulded case circuit breaker

Install a moulded case circuit breaker (MCCB) on the power receiving side to protect the wiring of the inverter input side. Select the MCCB according to the inverter input side power factor (which depends on the power supply voltage, output frequency and load). Especially for a completely electromagnetic MCCB, one of a slightly large capacity must be selected since its operation characteristic varies with harmonic currents. (Check it in the data of the corresponding breaker.) As an earth leakage circuit breaker, use the Mitsubishi earth leakage circuit breaker designed for harmonics and surge suppression.

Inverter

Thermal relay

Line-to-line static capacitances

Line-to-line leakage currents path

Motor

PRECAUTIONS FOR USE OF THE INVERTER

EMC and leakage currents

(3) Selection of rated sensitivity current of earth leakage circuit breaker

When using the earth leakage circuit breaker with the inverter circuit, select its rated sensitivity current as follows, independently of the PWM carrier frequency:

⋅ Breaker designed for harmonic and surge suppression

Rated sensitivity current: IΔn ≥ 10 × (Ig1 + Ign + Igi + Ig2 + Igm)

⋅ Standard breaker

Rated sensitivity current: IΔn ≥ 10 × {Ig1 + Ign + Igi + 3 × (Ig2 + Igm)}

Example of leakage current of cable path per 1km during the commercial power supply operation when the CV cable is routed in metal conduit

(200V 60Hz)

120

100

Leakage currents (mA)

23.5

8142230386080

5.5

Cable size (mm2)

100

150

Leakage current example of three-phase induction moto during the commercial power supply operation

(200V 60Hz)

2. 0

1. 0

0. 7

0. 5

0. 3

0. 2

0. 1

Leakage currents (mA)

1. 5 3.7

7. 5 152211373055

2. 2

Motor capacity (kW)

455.5 18. 5

5.5mm

ELB

Ig1 Ign

Noise

filter

2 ×

5m 5.5mm

Inverter

Igi

2 ×

40m

Ig2 Igm

3φ 200V

5.5kW

Leakage current Ig1 (mA) 33 ×

Leakage current Ign (mA) 0 (without noise filter)

Leakage current Igi (mA) 1

Leakage current Ig2 (mA) 33 ×

Motor leakage current Igm (mA) 0.29

Total leakage current (mA) 2.78 6.00

Rated sensitivity current (mA) (≥ Ig × 10) 30 100

Ig1, Ig2: Leakage currents in wire path during commercial

power supply operation Ign: Leakage current of inverter input side noise filter Igm: Leakage current of motor during commercial power

supply operation

Igi: Leakage current of inverter unit

Example of leakage current per 1km during the commercial power supply operation when the CV cable is routed in metal conduit

(Three-phase three-wire delta connection 400V60Hz)

120

100

23.5

8142230386080

size (mm2)

100

150

leakage currents (mA)

For " " connection, the amount of leakage current is appox.1/3 of the above value.

5.5

Cable

Leakage current example of threephase induction motor during the commercial power supply operation

(Totally-enclosed fan-cooled type motor 400V60Hz)

2. 0

1. 0

0. 7

0. 5

0. 3

0. 2

0. 1

1. 5 3.7

leakage currents (mA)

7. 5 152211373055

2. 2

Motor capacity (kW)

455.5 18. 5

Breaker Designed

for Harmonic and

Standard Breaker

Surge Suppression

1000m

40m

1000m

= 0.17

= 1.32

CAUTION

⋅ Install the earth leakage circuit breaker (ELB) on the input side of the inverter. ⋅ In the connection earthed-neutral system, the sensitivity current is blunt against an earth (ground) fault in the inverter output

side. Earthing (Grounding) must conform to the requirements of national and local safety regulations and electrical codes. (NEC section 250, IEC 536 class 1 and other applicable standards) Use a neutral-point earthed (grounded) power supply for 400V class inverter in compliance with EN standard.

⋅ When the breaker is installed on the output side of the inverter, it may be unnecessarily operated by harmonics even if the

effective value is less than the rating. In this case, do not install the breaker since the eddy current and hysteresis loss will increase, leading to temperature rise.

⋅ The following models are standard breakers....BV-C1, BC-V, NVB, NV-L, NV-G2N, NV-G3NA and NV-2F earth leakage relay

(except NV-ZHA), NV with AA neutral wire open-phase protection

The other models are designed for harmonic and surge suppression....NV-C/NV-S/MN series, NV30-FA, NV50-FA, BV-C2,

earth leakage alarm breaker (NF-Z), NV-ZHA, NV-H

EMC and leakage currents

3.1.2 EMC measures

Some electromagnetic noises enter the inverter to malfunction it and others are radiated by the inverter to malfunction peripheral devices. Though the inverter is designed to have high immunity performance, it handles low-level signals, so it requires the following basic techniques. Also, since the inverter chops outputs at high carrier frequency, that could generate electromagnetic noises. If these electromagnetic noises cause peripheral devices to malfunction, EMI measures should be taken to suppress noises. These techniques differ slightly depending on EMI paths.

1) Basic techniques

⋅ Do not run the power cables (I/O cables) and signal cables of the inverter in parallel with each other and do not

bundle them.

⋅ Use twisted shield cables for the detector connecting and control signal cables and connect the sheathes of the

shield cables to terminal SD.

⋅ Earth (Ground) the inverter, motor, etc. at one point.

2) Techniques to reduce electromagnetic noises that enter and malfunction the inverter (Immunity measures)) When devices that generate many electromagnetic noises (which use magnetic contactors, magnetic brakes, many relays, for example) are installed near the inverter and the inverter may be malfunctioned by electromagnetic noises, the following measures must be taken: ⋅ Provide surge suppressors for devices that generate many electromagnetic noises to suppress electromagnetic

noises.

⋅ Fit data line filters (page 38) to signal cables. ⋅ Earth (Ground) the shields of the detector connection and control signal cables with cable clamp metal.

3) Techniques to reduce electromagnetic noises that are radiated by the inverter to malfunction peripheral devices (EMI measures) Inverter-generated electromagnetic noises are largely classified into those radiated by the cables connected to the inverter and inverter main circuits (I/O), those electromagnetically and electrostatically induced to the signal cables of the peripheral devices close to the main circuit power supply, and those transmitted through the power supply cables.

Inverter generated electromagnetic noise

Air propagated

electromagnetic

noise

Electromagnetic

induction noise

Electrostatic

induction noise

Electrical path

propagated noise

Noise directly radiated from inverter

Noise radiated from power supply cable

Noise radiated from motor connection cable

Path 4), 5)

Path 6)

Noise propagated through power supply cable

Noise from earth (ground) cable due to leakage current

Path 1)

Path 2)

Path 3)

Path 7)

Path 8)

Instrument Receiver

Motor

Inverter

Telephone

Sensor

power supply

Sensor

PRECAUTIONS FOR USE OF THE INVERTER

EMC and leakage currents

Propagation Path Measures

When devices that handle low-level signals and are liable to malfunction due to electromagnetic noises, e.g. instruments, receivers and sensors, are contained in the enclosure that contains the inverter or when their signal cables are run near the inverter, the devices may be malfunctioned by air-propagated electromagnetic noises. The following measures must be taken: (1) Install easily affected devices as far away as possible from the inverter.

1) 2) 3)

4) 5) 6)

(2) Run easily affected signal cables as far away as possible from the inverter and its I/O cables. (3) Do not run the signal cables and power cables (inverter I/O cables) in parallel with each other and do

not bundle them.

(4) Insert common mode filters into I/O and capacitors between the input lines to suppress cable-

radiated noises.

(5) Use shield cables as 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 malfunction the devices and the following measures must be taken: (1) Install easily affected devices as far away as possible from the inverter. (2) Run easily affected signal cables as far away as possible from the I/O cables of the inverter. (3) Do not run the signal cables and power cables (inverter I/O cables) in parallel with each other and do

not bundle them.

(4) Use shield cables as 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 inverter in the same line, inverter-generated noises may flow back through the power supply cables to malfunction the devices. In such a case, installing the common mode filter (FR-BLF) to the power cables (output cable) of the inverter will prevent malfunction.

When a closed loop circuit is formed by connecting the peripheral device wiring to the inverter, leakage currents may flow through the earth (ground) cable of the inverter to malfunction the device. In such a case, disconnection of the earth (ground) cable of the device may cause the device to operate properly.

z Data line filter

Data line filter is effective as an EMC measure. Provide a data line filter for the detector cable, etc.

z EMC measures

Install common mode filter (FR-BLF) on inverter input side.

Inverter power supply

Install capacitor type FR-BIF filter on inverter input side.

Separate inverter and power line by more than 30cm (at least 10cm) from sensor circuit.

Control power supply

Do not earth (ground) enclosure directly.

Do not earth (ground) control cable.

Enclosure

FRBLF

FRBIF

Power supply

for sensor

Decrease carrier frequency

Inverter

FRBLF

Use a twisted pair shielded cable

Do not earth (ground) shield but connect it to signal common cable.

Install common mode filter (FR-BLF) on inverter output side.

Motor

Use 4-core cable for motor power cable and use one cable as earth (ground) cable.

Sensor

EMC and leakage currents

3.1.3 Power supply harmonics

The inverter may generate power supply harmonics from its converter circuit to affect the power generator, power capacitor etc. Power supply harmonics are different from noise and leakage currents in source, frequency band and transmission path. Take the following countermeasure suppression techniques. This inverter has a built-in AC reactor (FR-HAL) and a circuit type specified in Harmonic suppression guideline in Japan is three-phase bridge (capacitor smoothed) and with reactor (AC side).

3.1.4 Harmonic suppression guideline

Harmonic currents flow from the inverter to a power receiving point via a power transformer. The harmonic suppression guideline was established to protect other consumers from these outgoing harmonic currents. The three-phase 200V input specifications 3.7kW or less are previously covered by "Harmonic suppression guideline for household appliances and general-purpose products" and other models are covered by "Harmonic suppression guideline for consumers who receive high voltage or special high voltage". However, the general-purpose inverter has been excluded from the target products covered by "Harmonic suppression guideline for household appliances and general-purpose products" in January 2004. Later, this guideline was repealed on September 6, 2004. All capacities of all models are now target products of "Harmonic suppression guideline for consumers who receive high voltage or special high voltage" (hereinafter referred to as "Guideline for specific consumers").

"Guideline for specific consumers" This guideline sets forth the maximum values of harmonic currents outgoing from a high-voltage or especially highvoltage consumer who will install, add or renew harmonic generating equipment. If any of the maximum values is exceeded, this guideline requires that consumer to take certain suppression measures.

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

Received Power

Vol tage

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 0.24

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

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

Install, add or renew

equipment

Calculation of equivalent

Equal to or less than reference capacity

Above reference capacity

capacity total

Equivalent

capacity total

Calculation of outgoing

harmonic current

Not more than

harmonic current upper

limit?

Equal to or less than upper limit

Harmonic suppression

measures unnecessary

More than upper limit

Harmonic suppression

measures necessary

PRECAUTIONS FOR USE OF THE INVERTER

EMC and leakage currents

Table 2 Conversion factors for FR-A701 series

Class Circuit Type Conversion Factor (Ki)

Table 3 Equivalent Capacity Limits

Received Power Voltage Reference Capacity

6.6kV 50kVA

22/33kV 300kVA

66kV or more 2000kVA

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

Used (AC side) 38 14.5 7.4 3.4 3.2 1.9 1.7 1.3

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 consumer's harmonic generating equipment and is calculated with the following equation. If the sum of equivalent capacities is higher than the limit in Table 3, harmonics must be calculated with the following procedure:

Three-phase bridge (Capacitor smoothing)

With reactor (AC side) K32 = 1.8

Table 4 Harmonic content (Values of the fundamental current is 100%)

P0 = Σ (Ki × Pi) [kVA]

Ki: Conversion factor(According to Table 2) Pi: Rated capacity of harmonic generating equipment i : Number indicating the conversion circuit type

* [kVA]

* 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 required for actual inverter drive.

2)Calculation of outgoing harmonic current Outgoing harmonic current = fundamental wave current (value converted from received power voltage)

× operation

ratio × harmonic content

⋅ Operation ratio: Operation ratio = actual load factor × operation time ratio during 30 minutes ⋅ Harmonic content: Found in Table 4.

Table 5 Rated capacities and outgoing harmonic currents of inverter-driven motors

Rated Current

Applied

Motor

(kW)

5.5 19.1 9.55 579 6.77 220.0 83.96 42.85 19.69 18.53 11.00 9.843 7.527

7.5 25.6 12.8 776 9.07 294.9 112.5 57.42 26.38 24.83 14.74 13.19 10.09

11 36.9 18.5 1121 13.1 426.0 162.5 82.95 38.11 35.87 21.30 19.06 14.57

15 49.8 24.9 1509 17.6 573.4 218.8 111.7 51.31 48.29 28.67 25.65 19.62

18.5 61.4 30.7 1860 21.8 706.8 269.7 137.6 63.24 59.52 35.34 31.62 24.18

22 73.1 36.6 2220 25.9 843.6 321.9 164.3 75.48 71.04 42.18 37.74 28.86

30 98.0 49.0 2970 34.7 1129 430.7 219.8 101.0 95.04 56.43 50.49 38.61

37 121 60.4 3660 42.8 1391 530.7 270.8 124.4 117.1 69.54 62.22 47.58

45 147 73.5 4450 52.1 1691 645.3 329.3 151.3 142.4 84.55 75.65 57.85

55 180 89.9 5450 63.7 2071 790.3 403.3 185.3 174.4 103.6 92.65 70.85

(A)

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

Fundamental

Wave Current

Converted

from 6.6kV

(mA)

Rated

Capacity

(kVA)

Outgoing Harmonic Current Converted from 6.6kV (mA)

(With reactor, 100% operation ratio)

3)Harmonic suppression technique requirement If the outgoing harmonic current is higher than the maximum value per 1kW (contract power) × contract power, a harmonic suppression technique is required.

4)Harmonic suppression techniques

No. Item Description

Installation of power factor

improving capacitor

Transformer multi-phase

operation

Passive filter

(AC filter)

4 Active filter

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 impedances 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.

Power-off and magnetic contactor (MC)

3.2 Power-off and magnetic contactor (MC)

(1) Inverter input side magnetic contactor (MC)

On the inverter input side, it is recommended to provide an MC for the following purposes.

( Refer to page 3 for selection.)

1) To release the inverter from the power supply when the fault occurs or when the drive is not functioning (e.g. emergency stop operation). To prevent any accident due to an automatic restart at restoration of power after an inverter stop made by a power failure

3) To separate the inverter from the power supply to ensure safe maintenance and inspection work The inverter's input side MC is used for the above purpose, select class JEM1038-AC3MC for the inverter input side current when making an emergency stop during normal operation.

REMARKS

Since repeated inrush currents at power on will shorten the life of the converter circuit (switching life is about 500,000 times.), frequent starts and stops of the MC must be avoided. Turn ON/OFF the inverter start controlling terminals (STF, STR) to run/stop the inverter.

• Inverter start/stop circuit example

As shown on the left, always use the start signal (ON or

To the

OFF of STF (STR) signal) to make a start or stop.

motor

*1 When the power supply is 400V class, install a step-down

transformer.

*2 Connect the power supply terminals R1/L11, S1/L21 of the

control circuit to the input side of the MC to hold an alarm signal when the inverter's protective circuit is activated. At this time, remove jumpers across terminals R/L1-R1/L11 and S/L2-S1/L21. (Refer to page 19 for removal of the jumper.)

Operation preparation

OFF

Start/Stop

Start

Stop

Power supply

MCCB

R/L1

S/L2

T/L3

R1/L11

S1/L21

Inverter

STF(STR) SD

(2) Handling of the inverter output side magnetic contactor

Switch the magnetic contactor between the inverter and motor only when both the inverter and motor are at a stop. When the magnetic contactor is turned ON while the inverter is operating, overcurrent protection of the inverter and such will activate. When an MC is provided to switch to a commercial power supply, for example, it is recommended to

use bypass-inverter switchover function Pr. 135 to Pr. 139 (

Chapter 4 of the Instruction Manual (Applied)).

PRECAUTIONS FOR USE OF THE INVERTER

Inverter-driven 400V class motor

3.3 Inverter-driven 400V class motor

In the PWM type inverter, a surge voltage attributable to wiring constants is generated at the motor terminals. Especially for a 400V class motor, the surge voltage may deteriorate the insulation. When the 400V class motor is driven by the inverter, consider the following measures:

Measures

It is recommended to take either of the following measures:

(1) Rectifying the motor insulation and limiting the PWM carrier frequency according to the wiring length

For the 400V class motor, use an insulation-enhanced motor Specifically,

1)Specify the "400V class inverter-driven insulation-enhanced motor".

2)For the dedicated motor such as the constant-torque motor and low-vibration motor, use the "inverter-driven, dedicated motor".

3)Set Pr. 72 PWM frequency selection as indicated below according to the wiring length

50m or less 50m to 100m exceeding 100m

Pr. 72 PWM frequency selection 15 (14.5kHz) or less 9 (9kHz) or less 4 (4kHz) or less

(2) Suppressing the surge voltage on the inverter side

Connect the surge voltage suppression filter (FR-ASF-H/FR-BMF-H) on the inverter output side.

Wiring Length

CAUTION

· For explanation of surge voltage suppression filter (FR-ASF-H/FR-BMF-H), refer to the manual of each option.

· Do not perform Real sensorless vector control and vector control with a surge voltage suppression filter (FR-ASF-H) connected.

· A surge voltage suppression filter (FR-ASF-H/FR-BMF-H) can be used under V/F control and Advanced magnetic flux vector control.

Precautions for use of the inverter

3.4 Precautions for use of the inverter

The FR-A701 series is a highly reliable product, but incorrect peripheral circuit making or operation/handling method may shorten the product life or damage the product. Before starting operation, always recheck the following items.

(1) Use crimping terminals with insulation sleeve to wire the power supply and motor.

(2) Application of power to the output terminals (U, V, W) of the inverter will damage the inverter. Never perform

such wiring.

(3) After wiring, wire offcuts must not be left in the inverter.

Wire offcuts can cause an alarm, failure or malfunction. Always keep the inverter clean. When drilling mounting holes in an enclosure etc., take care not to allow chips and other foreign matter to enter the inverter.

(4) Use cables of the size to make a voltage drop 2% maximum.

If the wiring distance is long between the inverter and motor, a main circuit cable voltage drop will cause the motor torque to decrease especially at the output of a low frequency. Refer to page

(5) The overall wiring length should be within 500m with unshielded wires (within 100m for the operation under

vector control or when using shielded wires).

Especially for long distance wiring, the fast-response current limit function may decrease or the equipment connected to the output side may malfunction or become faulty under the influence of a charging current due to the stray capacity of the wiring. Therefore, note the overall wiring length. (Refer to page 18.)

16 for the recommended cable sizes.

(6) Electromagnetic wave interference

The input/output (main circuit) of the inverter includes high frequency components, which may interfere with the communication devices (such as AM radios) used near the inverter. In this case, connecting a capacitor type filter will reduce electromagnetic wave interference.

(7) Do not install a power factor correction capacitor, surge suppressor or capacitor type filter on the inverter

output side.

This will cause the inverter to trip or the capacitor, and surge suppressor to be damaged. If any of the above devices is installed, immediately remove it.

(8) For some short time after the power is switched off, a high voltage remains in the smoothing capacitor.

When accessing the inverter for inspection, wait for at least 10 minutes after the power supply has been switched off, and then make sure that the voltage across the main circuit terminals P/+-N/- of the inverter is not more than 30VDC using a tester, etc. The capacitor is charged with high voltage for some time after power off and it is dangerous.

(9) A short circuit or earth (ground) fault on the inverter output side may damage the inverter modules.

· Fully check the insulation resistance of the circuit prior to inverter operation since repeated short circuits caused by peripheral circuit inadequacy or an earth (ground) fault caused by wiring inadequacy or reduced motor insulation resistance may damage the inverter modules.

· Fully check the to-earth (ground) insulation and inter-phase insulation of the inverter output side before power-on. Especially for an old motor or use in hostile atmosphere, securely check the motor insulation resistance etc.

(10) Do not use the inverter input side magnetic contactor to start/stop the inverter.

Since repeated inrush currents at power ON will shorten the life of the converter circuit (switching life is about 500,000 times), frequent starts and stops of the MC must be avoided.

Always use the start signal (ON/OFF of STF and STR signals) to start/stop the inverter.

(Refer to page

12)

(11) Do not apply a voltage higher than the permissible voltage to the inverter I/O signal circuits.

Application of permissible voltage to the inverter I/O signal circuit and incorrect polarity may damage the I/O terminal. Especially check the wiring to prevent the speed setting potentiometer from being connected incorrectly to short terminals 10E-5.

(12) Provide electrical and mechanical interlocks for MC1

and MC2 which are used for bypass operation.

When the wiring is incorrect or if there is an electronic bypass circuit as shown on the right, the inverter will be damaged by leakage current from the power supply due to arcs generated at the time of switch-over or chattering caused by a sequence error. (Commercial operation can not be performed with the vector dedicated motor (SF-V5RU, SF-THY).)

Power supply

R/L1 S/L2 T/L3

Inverter

U V

Undesirable current

MC1

MC2

Interlock

PRECAUTIONS FOR USE OF THE INVERTER

Precautions for use of the inverter

(13) If the machine must not be restarted when power is restored after a power failure, provide a magnetic contactor

in the inverter's input side and also make up a sequence which will not switch on the start signal.

If the start signal (start switch) remains on after a power failure, the inverter will automatically restart as soon as the power is restored.

(14) Inverter input side magnetic contactor (MC)

On the inverter input side, connect a MC for the following purposes. (Refer to page 4 for selection.)

1)To release the inverter from the power supply when a fault occurs or when the drive is not functioning (e.g. emergency stop operation). For example, MC avoids overheat or burnout of the brake resistor when heat capacity of the resistor is insufficient or brake regenerative transistor is damaged with short while connecting an optional brake resistor.

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

3)To separate the inverter from the power supply to ensure safe maintenance and inspection work.

The inverter's input side MC is used for the above purpose, select class JEM1038-AC3 MC for the inverter input side current when making an emergency stop during normal operation.

(15) Handling of inverter output side magnetic contactor

Switch the magnetic contactor between the inverter and motor only when both the inverter and motor are at a stop. When the magnetic contactor is turned ON while the inverter is operating, overcurrent protection of the inverter and such will activate. When MC is provided for switching to the commercial power supply, for example, switch it ON/OFF after the inverter and motor have stopped.

(16) A motor with encoder is necessary for vector control. In addition, connect the encoder directly to the backlash-

free motor shaft. (An encoder is not necessary for Real sensorless vector control.)

(17) Countermeasures against inverter-generated EMI

If electromagnetic noise generated from the inverter causes frequency setting signal to fluctuate and motor rotation speed to be unstable when changing motor speed with analog signal, the following countermeasures are effective.

· Do not run the signal cables and power cables (inverter I/O cables) in parallel with each other and do not bundle them.

· Run signal cables as far away as possible from power cables (inverter I/O cables).

· Use shield cables as signal cables.

· Install a ferrite core on the signal cable (Example: ZCAT3035-1330 TDK).

(18) Instructions for overload operation

When performing an operation of frequent start/stop with the inverter, rise/fall in the temperature of the transistor element of the inverter will repeat due to a continuous flow of large current, shortening the life from thermal fatigue. Since thermal fatigue is related to the amount of current, the life can be increased by reducing current at locked condition, starting current, etc. Decreasing current may increase the life. However, decreasing current will result in insufficient torque and the inverter may not start. Therefore, choose the inverter which has enough allowance for current (up to 2 rank larger in capacity).

(19) Make sure that the specifications and rating match the system requirements.

Failsafe of the system which uses the

inverter

3.5 Failsafe of the system which uses the inverter

When a fault occurs, the inverter trips to output a fault signal. However, a fault output signal may not be output at an inverter

fault occurrence when the detection circuit or output circuit fails, etc. Although Mitsubishi assures best quality products,

provide an interlock which uses inverter status output signals to prevent accidents such as damage to machine when the

inverter fails for some reason and at the same time consider the system configuration where failsafe from outside the inverter,

without using the inverter, is enabled even if the inverter fails.

(1) Interlock method which uses the inverter status output signals

By combining the inverter status output signals to provide an interlock as shown below, an inverter alarm can be

detected.

No.

Interlock Method Check Method Used Signals Refer to Page

Inverter protective

1) function operation

2) Inverter running status Operation ready signal check

3) Inverter running status

4) Inverter running status

Operation check of an alarm contact Circuit error detection by negative logic

Logic check of the start signal and running signal

Logic check of the start signal and output current

Fault output signal (ALM signal)

Operation ready signal (RY signal)

Start signal (STF signal, STR signal) Running signal (RUN signal)

Start signal (STF signal, STR signal) Output current detection signal (Y12 signal)

Refer to Chapter 4 of the Instruction

Manual (Applied)

Refer to Chapter 4 of the Instruction

Manual (Applied)

Refer to Chapter 4 of the Instruction

Manual (Applied)

Refer to Chapter 4 of the Instruction

Manual (Applied)

1) Check by the output of the inverter fault signal

When the fault occurs and trips the inverter, the fault output

signal (ALM signal) is output (ALM signal is assigned to

terminal A1B1C1 in the initial setting).

Check that the inverter functions properly.

In addition, negative logic can be set (on when the inverter is

normal, off when the fault occurs).

2) Checking the inverter operating status by the inverter

operation ready completion signal

Operation ready signal (RY signal) is output when the

inverter power is ON and the inverter becomes operative.

Check if the RY signal is output after powering on the

inverter.

3) Checking the inverter operating status by the start signal

input to the inverter and inverter running signal.

The inverter running signal (RUN signal) is output when the

inverter is running (RUN signal is assigned to terminal RUN

in the initial setting).

Check if RUN signal is output when inputting the start signal

to the inverter (forward signal is STF signal and reverse

signal is STR signal). For logic check, note that RUN signal

is output for the period from the inverter decelerates until

output to the motor is stopped, configure a sequence

considering the inverter deceleration time

(when output

at NC contact)

Power

supply

ALM

RES

STF

Pr. 13 Starting frequency

Output frequency

RUN

Inverter fault occurrence (output shutoff)

Output frequency

OFF

Reset processing

(about 1s)

Reset ON

ON OFF

DC injection brake operation point

DC injection brake operation

Reset

processing

ON OFF

Time

PRECAUTIONS FOR USE OF THE INVERTER

Failsafe of the system which uses the

inverter

4) Checking the motor operating status by the start signal input to the inverter and inverter output current detection signal.

The output current detection signal (Y12 signal) is output when the inverter operates and currents flows in the motor.

Check if Y12 signal is output when inputting the start signal to the inverter (forward signal is STF signal and reverse

signal is STR signal). Note that the current level at which Y12 signal is output is set to 150% of the inverter rated current

in the initial setting, it is necessary to adjust the level to around 20% using no load current of the motor as reference with

Pr. 150 Output current detection level.

For logic check, as same as the inverter running signal (RUN signal), the inverter outputs for the period from the inverter

decelerates until output to the motor is stopped, configure a sequence considering the inverter deceleration time.

Output

Signal

ALM 99 199

RY 11 111

RUN 0 100

Y12 12 112

Pr. 190 to Pr. 196 Setting

Positive logic Negative logic

y When using various signals, assign functions to Pr.190 to Pr.

196 (output terminal function selection) referring to the table on

the left.

CAUTION

y Changing the terminal assignment using Pr. 190 to Pr. 196 (output terminal function selection) may affect the other functions. Set

parameters after confirming the function of each terminal.

(2) Backup method outside the inverter

Even if the interlock is provided by the inverter status signal, enough failsafe is not ensured depending on the failure

status of the inverter itself. For example, when the inverter CPU fails, even if the interlock is provided using the inverter

fault output signal, start signal and RUN signal output, there is a case where a fault output signal is not output and RUN

signal is kept output even if an inverter fault occurs.

Provide a speed detector to detect the motor speed and current detector to detect the motor current and consider the

backup system such as checking up as below according to the level of importance of the system.

1) Start signal and actual operation check

Check the motor running and motor current while the start signal is input to the inverter by comparing the start signal to

the inverter and detected speed of the speed detector or detected current of the current detector. Note that the motor

current runs as the motor is running for the period until the motor stops since the inverter starts decelerating even if the

start signal turns OFF. For the logic check, configure a sequence considering the inverter deceleration time. In addition, it

is recommended to check the three-phase current when using the current detector.

2) Command speed and actual operation check

Check if there is no gap between the actual speed and commanded speed by comparing the inverter speed command

and detected speed of the speed detector.

Controller

System failure

Inverter

To the alarm detection sensor

Sensor

(speed, temperature,

air volume, etc.)

Step of operation

4 DRIVING THE MOTOR

4.1 Step of operation

The inverter needs frequency command and start command. Frequency command (set frequency) determines the rotation speed of the motor. Turning ON the start command starts the motor to rotate. Refer to the flow chart below to perform setting.

: Initial setting

Frequency

(Hz)

Frequency command

Start command with

on the operation panel (PU)

How to

give a frequency

command?

Frequency command

Inverter output frequency

Time

(S)

Step of operation

Installation/mounting

Wiring of the power

supply and motor

System examination

How

to give a start

command?

{Refer to page 10}

{Refer to page 14}

{Refer to page 63, 66}

Start command using the PU connector and RS-485 terminal of the inverter and plug-in option (Communication)

Refer to Chapter 4 of

Connect a switch, relay, etc. to the control circuit terminal block of the inverter to give a start command. (External)

the Instruction Manual (Applied) .

How to

give a frequency

command?

Set from the PU (FR-DU07/ FR-PU04/ FR-PU07).

(PU)

{Refer to page 83} {Refer to page 86} {Refer to page 90} {Refer to page 88}

Change frequency with ON/OFF switches connected to terminals (multi-speed setting)

(External) (External) (External)

{Refer to page 92} {Refer to page 94} {Refer to page 98} {Refer to page 96}

Perform frequency setting by a current output device (Connection across

terminals 4-5)

Set from the PU (FR-DU07/ FR-PU04/ FR-PU07).

(PU) (External) (External) (External)

Change of frequency with ON/OFF switches connected to terminals (multi-speed setting)

Perform frequency setting by a voltage output device (Connection across

terminals 2-5)

Perform frequency setting by a current output device (Connection across terminals 4-5)

Perform frequency setting by a voltage output device (Connection across terminals 2-5)

CAUTION

Check the following items before powering ON the inverter.

· Check that the inverter is installed correctly in a correct place. (Refer to page 10)

· Check that wiring is correct. (Refer to page 12)

· Check that no load is connected to the motor.

·When protecting the motor from overheat by the inverter, set Pr.9 Electronic thermal O/L relay (Refer to

page 57)

· When the rated frequency of the motor is 50Hz, set Pr.3 Base frequency (Refer to page 58)

DRIVING THE MOTOR

Operation panel (FR-DU07)

4.2 Operation panel (FR-DU07)

4.2.1 Parts of the operation panel (FR-DU07)

Operation mode indicator

PU: Lit to indicate PU operation mode. EXT: Lit to indicate External operation mode. NET: Lit to indicate Network operation mode.

Unit indicator

· Hz: Lit to indicate frequency.

· A: Lit to indicate current.

· V: Lit to indicate voltage.

(Flicker when the set frequency monitor is displayed.)

Rotation direction indicator

FWD: Lit during forward rotation REV: Lit during reverse rotation

Lit: Forward/reverse operation Flickering: When the frequency command is not

given even if the forward/reverse command is given. When the MRS signal is input.

Monitor indicator

Lit to indicate monitoring mode.

Monitor (4-digit LED)

Shows the frequency, parameter number, etc.

Setting dial

(Setting dial: Mitsubishi inverter dial)

Used to change the frequency setting and parameter settings.

Mode switchover

Used to change each setting mode.

No function

Start command forward rotation

Start command reverse rotation

Stop operation

Used to stop Run command. Fault can be reset when protective function is activated (fault).

Used to set each setting. If pressed during operation, monitor changes as below;

Running frequency

* Energy saving monitor is displayed when the

energy saving monitor of Pr. 52 is set.

Output current

Output voltage

Operation mode switchover

Used to switch between the PU and External operation mode. When using External operation mode (operation using a separately connected frequency setting potentiometer and start signal), press this key to light up the EXT indicator. (Change the Pr.79 setting to use the combined mode.) PU: PU operation mode EXT: External operation mode

4.2.2 Basic operation (factory setting)

Operation mode switchover

At power-ON (External operation mode)

Operation panel (FR-DU07)

PU Jog operation mode

PU operation mode

(output frequency monitor)

Monitor/frequency setting

Parameter setting mode

Parameter settingFaults history

(Refer to page 52)

Output current monitor

Value change

(Example)

and frequency flicker.

Frequency setting has been written and completed!!

Output voltage monitor

Display the present setting

(Example)

Parameter and a setting value flicker alternately.

Parameter write is completed!!

Parameter clear All parameter

[Operation for displaying faults history]

Past eight faults can be displayed.

(The latest fault is ended by ".".)

When no fault history exists, is displayed.

clear

(Refer to page 160)

Parameter copy

Fault clear

DRIVING THE MOTOR

Operation panel (FR-DU07)

Turn until appears.

4.2.3 Operation lock (Press [MODE] for an extended time (2s))

Operation using the setting dial and key of the operation panel can be invalid to prevent parameter change, and unexpected start or frequency setting.

· Set "10 or 11" in Pr. 161, then press for 2s to make the setting dial and key operation invalid.

· When the setting dial and key operation are invalid, appears on the operation panel.

If dial and key operation is attempted while dial and key operation are invalid, appears. (When dial or key is not touched for 2s, the monitor display appears.)

· To make the setting dial and key operation valid again, press for 2s.

POINT

Set "10 or 11" (key lock valid) in Pr.161 Frequency setting/key lock operation selection.

Operation

1.Screen at power-ON

The monitor display appears.

2.Press to choose the PU

operation mode.

3.Press to choose the parameter

setting mode.

(Pr. 161)

5.Press to read the currently set value.

" " (initial value) appears.

6.Turn to change it to the setting

value " ".

7.Press to set.

Display

PU indicator is lit.

The parameter number read previously appears.

Flicker ··· Parameter setting complete!!

8.Press for 2s to show the key lock.

Stop and reset with .

CAUTION

Release the operation lock to release the PU stop by key operation.

Press for 2s.

Functions valid even in the operation lock status

Operation panel (FR-DU07)

4.2.4 Monitoring of output current and output voltage

POINT

Monitor display of output frequency, output current, and output voltage can be changed by pushing during

monitoring mode.

Operation

Display

1.Press during operation to choose the output

frequency monitor

2.Independently of whether the inverter is running

in any operation mode or at a stop, the output

current monitor appears by pressing .

3.Press to show the output voltage monitor.

4.2.5 First priority monitor

Hold down for 1s to set monitor description to be appeared first in the monitor mode.

(To return to the output frequency monitor, hold down for 1s after displaying the output frequency monitor.)

4.2.6 Setting dial push

Push the setting dial ( ) to display the set frequency currently set.

DRIVING THE MOTOR

Operation panel (FR-DU07)

Turn to change it to the set

value " ".

4.2.7 Changing the parameter setting value

Changing example Change the Pr. 1 Maximum frequency .

Operation

1.Screen at power-ON

The monitor display appears.

2.Press to choose the PU operation

mode.

3.Press to choose the parameter

setting mode.

4. Pr. 1) appears.

5.Press to read the currently set value.

" "(initial value) appears.

7.Press to set.

· By turning , you can read another parameter.

· Press to show the setting again.

· Press twice to show the next parameter.

· Press twice to return the monitor to frequency monitor.

Display

PU indicator is lit.

The parameter number read previously appears.

Flicker ··· Parameter setting complete!!

For details refer to page 143.

REMARKS

The number of digits displayed on the operation panel (FR-DU07) is four. If the values to be displayed have five digits or more including decimal places, the fifth or later numerals can not be displayed nor set.

(Example) When Pr. 1 When 60Hz is set, 60.00 is displayed. When 120Hz is set, 120.0 is displayed and second decimal place is not displayed nor set.

are displayed ... Why?

appears. ...... Write disable error

appears. ...... Write error during operation

appears. ...... Calibration error

appears. ..... Mode designation error

Operation panel (FR-DU07)

4.2.8 Parameter clear, all parameter clear

POINT

· Set "1" in Pr. CL parameter clear or ALLC all parameter clear to initialize all parameters. (Parameters are not cleared

when "1" is set in Pr. 77 Parameter write selection. )

· Refer to the parameter list on page 103 and later for parameters to be cleared with this operation.

Operation

Screen at power-ON

The monitor display appears.

Press to choose the PU operation

mode.

Press to choose the parameter

setting mode.

Turn until " ", " "

appears.

Press to read the currently set value.

" "(initial value) appears.

Turn clockwise to change it to

the setting value of " ".

Press to set.

· Turn to read another parameter.

Display

PU indicator is lit.

The parameter number read previously appears.

Parameter clear All parameter clear

Parameter clear

Flicker ··· Parameter setting complete!!

All parameter clea

· Press to show the setting again.

· Press twice to show the next parameter.

and are displayed alternately ... Why?

The inverter is not in PU operation mode.

1. Press .

is lit and the monitor (4-digit LED) displays "0" (Pr. 79 = "0" (initial value)).

2. Carry out operation from step 6 again.

DRIVING THE MOTOR

Operation panel (FR-DU07)

4.2.9 Parameter copy and parameter verification

PCPY Setting Description

0 Cancel 1 Copy the source parameters to the operation panel. 2 Write the parameters copied to the operation panel into the destination inverter. 3 Verify parameters in the inverter and operation panel. (Refer to page 55.)

REMARKS

· When the copy destination inverter is not the FR-A701 series or parameter copy write is performed after parameter copy read is

stopped, "model error ( )" is displayed.

· Refer to the

· When the power is turned OFF or an operation panel is disconnected, etc. during parameter copy write, perform write again or check the values by parameter verification.

· Initial settings of certain parameters are different for different capacities, so some parameter settings may be automatically changed when parameter copy is performed from a different-capacity inverter. After performing a parameter copy from a different-capacity inverter, check the parameter settings. (Refer to the parameter list (page 103) for the parameters with different initial settings for different capacities.)

(1) Parameter copy

Parameter settings can be copied to multiple inverters.

parameter list on page 103 and later for availability of parameter copy.

Operation

1.Connect the operation panel to the

copy source inverter.

• Connect it during a stop.

2.Press to choose the parameter

setting mode.

3.Turn until (parameter copy)

appears.

4.Press to to read the currently set value.

" "(initial value) appears.

5.Turn to change it to the setting value

" ".

6.Press to copy the source parameters

to the operation panel.

7.Connect the operation panel to the

copy source inverter.

Display

The parameter number previously read appears.

Flickers for about 30s

About 30s later

Flicker ··· Parameter copy complete!!

8.After performing steps 2 to 5,

turn to change it to " ".

9.Press to write the parameters copied to

the operation panel to the destination inverter.

10.When copy is completed,

" " and " " flicker.

Flicker ··· Parameter copy complete!!

11.After writing the parameter values to the copy

destination inverter, always reset the inverter, e.g. switch power OFF once, before starting operation.

The frequency flickers for about 30s

appears...Why? Parameter read error. Perform operation from step 3 again.

appears...Why? Parameter write error. Perform operation from step 8 again.

(2) Parameter verification

Whether same parameter values are set in other inverters or not can be checked.

Operation panel (FR-DU07)

Operation

1.Move the operation panel to the

inverter to be verified.

• Move it during a stop.

2.Screen at power-ON

The monitor display appears.

3.Press to choose the parameter

setting mode.

4.Turn until (parameter copy)

appears.

5.Press to read the currently set

value. " "(initial value) appears.

6.Turn to change it to the set value

" "(parameter copy verification mode).

7.Press to read the parameter setting

of the verified inverter to the operation panel.

Display

The parameter number read previously appears.

Flickers for about 30s

• If different parameters exist, different

parameter numbers and flicker.

• Hold down to verify.

8.It there is no difference, " " and " "

flicker to complete verification.

Flicker ··· Parameter verification complete!!

flickers ... Why?

Set frequencies, etc. may be different. Check set frequencies.

Flickering

DRIVING THE MOTOR

Before operation

4.3 Before operation

4.3.1 Simple mode parameter list

For simple variable-speed operation of the inverter, the initial setting of the parameters may be used as they are. Set the necessary parameters to meet the load and operational specifications. Parameter setting, change and check can

be made from the operation panel (FR-DU07). For details of parameters, refer to Chapter 4 of the Instruction Manual (Applied).

POINT

Only simple mode parameter can be displayed using Pr.160 User group read selection. (All parameters are displayed with the initial setting.) Set Pr. 160 User group read selection as required. (Refer to page 52 for parameter change.)

Pr. 160 Description

9999 Only the simple mode parameters can be displayed.

(Initial Value)

1 Only the parameters registered in the user group can be displayed.

Simple mode and extended mode parameters can be displayed.

Parameter

Number

0 Torque boost 0.1% 3/2%*1 0 to 30%

3 Base frequency

7 Acceleration time

8 Deceleration time

125

126

160

Name

Maximum frequency

Minimum frequency

Multi-speed setting (high speed)

Multi-speed setting (middle speed)

Multi-speed setting (low speed)

Electronic thermal O/L relay

Operation mode selection

Terminal 2 frequency setting gain frequency

Terminal 4 frequency setting gain frequency

User group read selection

Incre

ments

0.01Hz 120Hz 0 to 120Hz

0.01Hz 0Hz 0 to 120Hz

0.01Hz 60Hz 0 to 400Hz

0.01Hz 30Hz 0 to 400Hz

0.01Hz 10Hz 0 to 400Hz

0.1s 5/15s*2 0 to 3600s

0.01A

0.01Hz 60Hz 0 to 400Hz

Initial Value

Inverter

rated

current

1 0 0, 1, 2, 3, 4, 6, 7

1 0 0, 1, 9999

Range Applications

Set to increase a starting torque or when the motor with a load will not rotate, resulting in an alarm [OL] and a trip [OC1]

*1 The initial value differs according to the inverter

capacity. (7.5K or lower/11K or higher)

Set when the maximum output frequency need to be limited.

Set when the minimum output frequency need to be limited.

Set when the rated motor frequency is 50Hz. Check the motor rating plate.

Set when changing the preset speed in the parameter with a terminal.

Acceleration/deceleration time can be set.

*2 The initial value differs according to the inverter

capacity. (7.5K or lower/11K or higher)

0 to 500A

Protect the motor from overheat by the inverter. Set the rated motor current.

Select the operation command location and frequency command location.

Frequency for the maximum value of the potentiometer (5V initial value) can be changed.

Frequency for the maximum current input (20mA initial value) can be changed.

Parameter which can be read from the operation panel and parameter unit can be restricted.

Refer

Page

945

—

4.3.2 Overheat protection of the motor by the inverter (Pr. 9)

Set the rated motor current in Pr. 9 Electronic thermal O/L relay to protect the motor from overheat.

Before operation

Parameter

Number

Name Initial Value Setting Range *2 Description

9 Electronic thermal O/L relay

*1 Refer to page 182 for the rated inverter current value. *2 The minimum setting increments are 0.01A.

Changing example

Change the Pr. 9 Electronic thermal O/L relay setting to 22A according to the motor rated current. (FR-A721-5.5K)

Operation

1.Screen at power-ON

The monitor display appears.

2.Press to choose PU operation

mode.

3.Press to choose the parameter

setting mode.

4.Turn until Pr. 9 Electronic

thermal O/L relay appears.

5.Press to show the present

set value.

(24A for FR-A721-5.5K)

6.Turn to change the set value

" ". (22A)

Inverter rated

current

0 to 500A Set the rated motor current.

Display

PU indicator is lit.

The parameter number read previously appears.

Refer to page 182 for initial

value of the inverter rated current.

7.Press to set.

Flicker ··· Parameter setting complete!!

· By turning , you can read another parameter.

· Press to show the setting again.

· Press twice to show the next parameter.

REMARKS

· Since a thermal protector is provided for a vector control dedicated motor (SF-V5RU), set "0" in Pr. 9.

CAUTION

· Protective function by electronic thermal relay function is reset by inverter power reset and reset signal input. Avoid unnecessary reset and power-OFF.

· When two or more motors are connected to the inverter, they cannot be protected by the electronic thermal relay function. Install an external thermal relay to each motor.

· When the difference between the inverter and motor capacities is large and the setting is small, the protective characteristics of the electronic thermal relay function will be deteriorated. In this case, use an external thermal relay.

· A special motor cannot be protected by the electronic thermal relay function. Use an external thermal relay.

· PTC thermistor output built-in the motor can be input to the PTC signal (AU terminal). For details, refer to Chapter 4 of the Instruction Manual (Applied).

DRIVING THE MOTOR

Before operation

V/F

4.3.3 When the rated motor frequency is 50Hz (Pr. 3)

First, check the motor rating plate. If a frequency given on the rating plate is "50Hz" only, always set Pr. 3 Base frequency to "50Hz". Leaving the base frequency unchanged from "60Hz" may make the voltage low and the torque insufficient. It may result in an inverter trip (E.OC) due to overload.

Parameter

Number

3 Base frequency

Changing example Change Pr. 3 Base frequency to 50Hz according to the motor rated frequency.

Name Initial Value Setting Range Description

60Hz 0 to 400Hz

Operation

V/F

Set the frequency when the motor rated torque is generated.

Display

1.Screen at power-ON

The monitor display appears.

2.Press to choose the PU operation

mode.

3.Press to choose parameter

setting mode.

PU indicator is lit.

The parameter number read previously appears.

4.Turn until Pr. 3 Base frequency

appears.

5.Press to show the currently set

value. (60Hz)

6.Turn to change it to

the set value " ". (50Hz)

7.Press to set.

Flicker ··· Parameter setting complete!!

· Press to show the setting again.

· Press twice to show the next parameter.

REMARKS

· Pr. 3 is invalid and Pr.84 Rated motor frequency is valid under Advanced magnetic flux vector control, Real sensorless vector control, and vector control.

Before operation

V/F

P P P

4.3.4 Increase the starting torque (Pr. 0)

V/F

Set this parameter when "the motor with a load will not rotate", "an alarm [OL] is output, resulting in an inverter trip due to [OC1], etc.

Parameter

Number

0 Torque boost

Changing example

Name Initial Value

7.5K or lower

11K or higher

When the motor with a load will not rotate, increase the Pr. 0 value 1% by 1% unit by looking at the motor movement. (The guideline is for about 10% change at the greatest.)

Operation

Setting

Range

0 to 30%

Description

Motor torque in the low-frequency range can be adjusted to the load to increase the starting motor torque.

100%

Output voltage

r. 0

Setting

r.46

range

r. 11 2

Output frequency (Hz)

Base frequency

Display

1.Screen at power-ON

The monitor display appears.

2.Press to choose PU operation mode.

3.Press to choose the parameter

setting mode.

4. Pr. 0) appears.

5.Press to read the currently set value.

" "(initial value is 3% for the 5.5K) appears.

6.Turn to change it to the set value

" ".

7.Press to set.

· By turning , you can read another parameter.

· Press to show the setting again.

· Press twice to show the next parameter.

PU indicator is lit.

The parameter number read previously appears.

The initial value differs according to the capacity.

Flicker ··· Parameter setting complete!!

REMARKS

· A too large setting may cause the motor to overheat, resulting in an overcurrent trip (OL (overcurrent alarm) then E.OC1 (overcurrent trip during acceleration)), overload trip (E.THM (motor overload trip), and E.THT (inverter overload trip)). (When a fault occurs, release the start command, and decrease the Pr. 0 setting 1% by 1% to reset.)

POINT

If the inverter still does not operate properly after the above measures, adjust Pr. 80, Pr. 81 (Advanced magnetic flux vector control), Pr.800 (Real sensorless vector control). The Pr.0 setting is invalid under Advanced magnetic flux

DRIVING THE MOTOR

vector control, Real sensorless vector control and vector control. (Refer to Chapter 4 of the Instruction Manual (Applied).)

Before operation

Turn to change it to the set

value " ".

4.3.5 Limit the maximum and minimum output frequency (Pr. 1, Pr. 2)

Motor speed can be limited.

Parameter

Number

Name Initial Value Setting Range Description

1 Maximum frequency 2 Minimum frequency

Changing example

Limit the frequency set by the potentiometer, etc. to 60Hz maximum. (Set "60"Hz in Pr. 1 Maximum frequency.)

1.Screen at power-ON

The monitor display appears.

2.Press to choose the PU operation

mode.

3.Press to choose the parameter

setting mode.

Operation

120Hz 0 to 120Hz Set the upper limit of the output frequency.

0Hz 0 to 120Hz Set the lower limit of the output frequency.

Clamped at the

Output frequency (Hz)

Pr.1 Pr.18

Pr.2

Clamped at the minimum fre

uenc

(4mA)

maximum frequenc

Frequency setting

5, 10V

(20mA)

Display

PU indicator is lit.

The parameter number read previously appears.

4. Pr. 1) appears.

5.Press to read the currently set value.

" "(initial value) appears.

7.Press to set.

Flicker ··· Parameter setting complete!!

· By turning , you can read another parameter.

· Press to show the setting again.

· Press twice to show the next parameter.

REMARKS

· The output frequency is clamped by the Pr. 2 setting even if the set frequency is lower than the Pr. 2 setting (The frequency will not decrease to the Pr. 2 setting.) Note that Pr. 15 Jog frequency has higher priority than the minimum frequency.

· When the Pr. 1 setting is changed, frequency higher than the Pr. 1 setting can not be set by .

· When performing a high speed operation at 120Hz or more, setting of Pr. 18 High speed maximum frequency is necessary.

(Refer to Chapter 4 of the Instruction Manual (Applied).)

If the Pr. 2 setting is higher than the Pr. 13 Starting frequency value, note that the motor will run at the set frequency according to the acceleration time setting by merely switching the start signal on, without entry of the command frequency.

CAUTION

Before operation

4.3.6 Change acceleration and deceleration time (Pr. 7, Pr. 8)

Set in Pr. 7 Acceleration time a larger value for a slower speed increase and a smaller value for a faster speed increase. Set in Pr. 8 Deceleration time a larger value for a slower speed decrease and a smaller value for a faster speed decrease.

Parameter

Number

7 Acceleration time

8 Deceleration time

* Depends on the Pr. 21 Acceleration/deceleration time increments setting. The initial value for the setting range is "0 to 3600s" and setting increments is

"0.1s".

Name Initial Value Setting Range Description

7.5K or lower

11K or higher

7.5K or lower

11K or higher

15s

0 to 3600/360s

* Set the motor acceleration time.

* Set the motor deceleration time.

Changing example Change the Pr. 7 Acceleration time setting from "5s" to

"10s".

Operation

Pr.20

(60Hz)

Output

Acceleration time

Display

(Hz)

frequency

Pr.7 Pr.44 Pr.110

Running frequency

Deceleration time

Time

Pr.8 Pr.45 Pr.111

1.Screen at power-ON

The monitor display appears.

2.Press to choose the PU operation

mode.

PU indicator is lit.

3.Press to choose the parameter

setting mode.

4. Pr. 7) appears.

5.Press to read the currently set value.

" "(initial value) appears.

6.Turn to change it to the set

value " ".

7.Press to set.

· By turning , you can read another parameter.

· Press to show the setting again.

· Press twice to show the next parameter.

The parameter number read previously appears.

The initial value differs according to the capacity.

Flicker ··· Parameter setting complete!!

DRIVING THE MOTOR

Before operation

4.3.7 Selection of the start command and frequency command locations (Pr. 79)

Select the start command location and frequency command location.

Parameter

Number

Name

Initial Val ue

Setting

Range

Description

Use External/PU switchover mode (press to switch

between the PU and External operation mode. (Refer to page 83)) At power on, the inverter is in External operation mode.

LED Indication

: Off : On

PU operation mode

External operation mode

NET operation mode

PU operation mode

1 Fixed to PU operation mode

External operation mode

Fixed to External operation mode

Operation can be performed by switching between the external and NET operation mode.

NET operation mode

External/PU combined operation mode 1

Frequency command Start command

PU (FR-DU07/FR-PU04/ FR-PU07) setting or

external signal input (multispeed setting, across terminals 4-5 (valid when AU signal turns on)).

External signal input (terminal STF, STR)

External/PU combined operation mode

Operation mode selection

External/PU combined operation mode 2

Frequency command Start command

External signal input (Terminal 2, 4, 1, JOG, multi-speed selection, etc.)

Input from the PU (FRDU07/FR-PU04/FR-PU07)

(, )

Switchover mode

Switch among PU operation, external operation, and NET operation while keeping the same operating status.

PU operation mode

External operation mode (PU operation interlock) X12 signal ON

External operation mode

Operation mode can be switched to PU operation

mode. (output stop during external operation)

X12 signal OFF

NET operation mode

Operation mode can not be switched to the PU operation mode.

*1 The priorities of the frequency commands when Pr. 79 = "3" are "Multi-speed operation (RL/RM/RH/REX) > PID control (X14) > terminal 4 analog

input (AU) > digital input from the operation panel".

*2 For the terminal used for the X12 signal (PU operation interlock signal) input, set "12" in Pr. 178 to Pr. 189 (input terminal function selection) to assign

functions.

For Pr. 178 to Pr. 189, refer to Chapter 4 of the Instruction Manual (Applied). When the X12 signal is not assigned, function of the MRS signal switches from MRS (output stop) to PU operation interlock signal.

Before operation

Magnetic flux

Sensorless

4.3.8 Large starting torque and low speed torque are necessary (Advanced magnetic flux vector control, Real sensorless vector control) (Pr. 71, Pr. 80, Pr. 81, Pr. 800)

Magnetic flux

Advanced magnetic flux vector control can be selected by setting the capacity, poles and type of the motor used in Pr. 80 and Pr. 81. Real sensorless vector control can be selected for applications requiring high accuracy and fast response

control. Perform offline auto tuning and online auto tuning when using Real sensorless vector control.

• What is Advanced magnetic flux vector control?

The low speed torque can be improved by providing voltage compensation to flow a motor current which meets the load torque. Output frequency compensation (slip compensation) is made so that the motor actual speed approximates a speed command value. Effective when load fluctuates drastically, etc. Low-speed torque is improved as compared to V/F control. In addition, speed accuracy is improved when load is applied.

• What is Real sensorless vector control?

This function enables vector control with a general-purpose motor without encoder. Low speed torque and speed accuracy are improved as compared to Advanced magnetic flux vector control. Always perform offline auto tuning and online auto tuning when using Real sensorless vector control. Real sensorless vector control is suitable for the following applications.

· To minimize the speed fluctuation even at a severe load fluctuation

· To generate low speed torque

· To prevent machine from damage due to too large torque (torque limit)

· To perform torque control

Sensorless

Parameter

Number

Name

71 Applied motor

80 Motor capacity 9999

81 Number of motor poles 9999

800 Control method selection 20

* Use Pr. 178 to Pr. 189 to assign the terminals used for the X18 and MC signal. (Refer to Chapter 4 of the Instruction Manual (Applied).)

Initial Value

Setting Range Description

0 to 8, 13 to 18, 30, 33, 34,

40, 43, 44, 50, 53, 54

0.4 to 55kW Set the applied motor capacity.

9999 V/F control

2, 4, 6, 8, 10 Set the number of motor poles.

12, 14, 16, 18, 20

9999 V/F control

0 to 5 Vector control (Refer to page 66)

9 Vector control test operation

10 Speed control

11 Torque control

By selecting a standard motor or constanttorque motor, thermal characteristic and motor constants of each motor are set.

X18 signal-ON:V/F control

MC signal-ON:torque MC signal-OFF:speed

V/F control (Advanced magnetic flux vector control)

Set 10 + number of motor poles.

Real sensorless vector control

POINT

If the following conditions are not satisfied, select V/F control since malfunction such as insufficient torque and uneven rotation may occur.

· The motor capacity should be equal to or one rank lower than the inverter capacity.

· Motor to be used is either Mitsubishi standard motor (SF-JR 3.7kW or higher), high efficiency motor (SF-HR 3.7kW or higher) or Mitsubishi constant-torque motor (SF-JRCA 4P, SF-HRCA 3.7kW or more). When using a motor other than the above (other manufacturer's motor), perform offline auto tuning without fail. (Advanced magnetic flux vector control) When performing Real sensorless vector control, offline auto tuning are necessary even when Mitsubishi motor is used.

· Single-motor operation (one motor run by one inverter) should be performed.

· The wiring length from inverter to motor should be within 30m. (Perform offline auto tuning in the state where actual wiring work is performed when the wiring length exceeds 30m.)

CAUTION

· Uneven rotation slightly increases as compared to the V/F control. (It is not suitable for machines such as grinding machine and wrapping machine which requires less uneven rotation at low speed.)

· Changing the terminal assignment using Pr. 178 to Pr. 189 (input terminal function selection) may affect the other functions. Please make setting after confirming the function of each terminal.

· When Advanced magnetic flux vector control is performed with a surge voltage suppression filter (FR-ASF-H) connected, output torque may decrease.

· Do not perform Real sensorless vector control with a surge voltage suppression filter (FR-ASF-H) connected.

DRIVING THE MOTOR

Before operation

Perform secure wiring. (Refer to page 12.)

Set the motor. (Pr. 71) (Refer to page 63.)

Motor Pr. 71 Setting *1 Remarks

Mitsubishi standard

motor

Mitsubishi high

efficiency motor

Mitsubishi constant-

torque motor

Other manufacturer's standard motor

Other manufacturer's

constant-torque

motor

*1 For other settings of Pr. 71 , refer to Chapter 4 of the Instruction Manual (Applied). *2 Refer to page 71 for offline auto tuning.

SF-JR 0 (initial value)

SF-HR 40

Others 3

SF-JRCA 4P 1

SF-HRCA 50

Others (SF-JRC, etc.) 13

−

Offline auto tuning is necessary.

Set the motor capacity and the number of motor poles according as required.

(Pr. 80, Pr. 81) (Refer to page 63.)

Set the motor capacity (kW) in

Pr. 80 Motor capacity

of motor poles (number of poles) in control is performed when the setting is "9999" (initial value).

Set the run command. (Refer to page 83.)

Select the start command and speed command. (1) Start command

1) Operation panel: Setting by pressing / of the operation panel

2) External command: Setting by forward rotation or reverse rotation command (terminal STF or STR)

(2)Speed command

Operation panel: Setting by pressing of the operation panel

2) External analog command (terminal 2 or 4) : Give a speed command using the analog signal input to terminal 2 (or terminal 4).

3) Multi-speed command: The external signals (RH, RM, RL) may also be used to give speed command.

Test run

As required

· Perform offline auto tuning. (Pr.96) (refer to page 71).

· Select online auto tuning. (Pr.95) (refer to page

76).

Pr. 81 Number of motor poles

and set the number

. (V/F

REMARKS

· When higher accuracy operation is necessary, set Real sensorless vector control after performing offline auto tuning and select Real sensorless vector control.

·Use Pr. 89 to adjust the motor speed fluctuation at load fluctuation. (Refer to Chapter 4 of the Instruction Manual (Applied).)

Speed control is exercised to match the speed command and actual motor speed.

Perform secure wiring. (Refer to page 12.)

Set the motor. (Pr. 71) (Refer to page 64.)

Set "3" (standard motor) or "13" (constant-torque motor) in Pr. 71 Applied motor.

Set the motor capacity and the number of motor poles.

(Refer to page 75.)

Set the motor capacity (kW) in Pr. 80 Motor capacity and set the number of motor poles (number of poles) in Pr. 81 Number of motor poles. (V/F control is performed when the setting is "9999" (initial value).)

Select a control method

. (Refer to page 63)

Set "10" (speed control) or "12" (speed-torque switchover) in Pr. 800 and make speed control valid.

Set the operation command. (Refer to page 83 )

Select the start command and speed command. (1) Start command

1) Operation panel: Setting by pressing / of the operation panel

2) External command: Setting by forward rotation and reverse rotation command (terminal STF or STR)

(2) Speed command

(Pr. 80, Pr. 81)

Before operation

1) Operation panel: Setting by turning of the operation panel

2) External analog command (terminal 2 or 4) : Give a speed command using the analog signal input to terminal 2 (or terminal 4).

3) Multi-speed command: The external signals (RH, RM, RL) may also be used to give speed command.

Set the torque limit. (Pr. 810)

(Refer to Chapter 4 of the Instruction Manual (Applied).)

Perform offline auto tuning. (Pr. 96) (Refer to page 71.)

Test run

As required

⋅ Easy gain tuning (Refer to page 77) ⋅ Select online auto tuning. (Pr. 95) (Refer to page 76) ⋅ Manual input speed control gain adjustment (Refer to page 79)

CAUTION

⋅ Make sure to perform offline auto tuning before performing Real sensorless vector control. ⋅ Speed command setting range is 0 to 120Hz for Real sensorless vector control. ⋅ The carrier frequencies are selectable from among 2k, 6k, 10k, 14kHz for Real sensorless vector control. ⋅ Torque control can not be performed in the low speed (approx. 10Hz or less) regeneration range and with light load at low speed

(approx. 20% or less of rated torque at approx. 5Hz or less). Choose vector control.

⋅ Performing pre-excitation (LX signal and X13 signal) under torque control may start the motor running at a low speed even when

the start command (STF or STR) is not input. The motor may run also at a low speed when the speed limit value = 0 with a start command input. Perform pre-excitation after making sure that there will be no problem in safety if the motor runs.

⋅ Do not switch between the STF (forward rotation command) and STR (reverse rotation command) during operation under torque

control. Overcurrent trip (E.OC) or opposite rotation deceleration fault (E.11) occurs.

⋅ When the inverter is likely to start during motor coasting under Real sensorless vector control, set to make frequency search of

automatic restart after instantaneous power failure valid (Pr. 57 ≠ "9999", Pr. 162 = "10").

⋅ Enough torque may not be generated in the ultra-low speed range less than approx. 2Hz when performing Real sensorless

vector control. The guideline of speed control range is as shown below. Driving: 1:200 (2, 4, 6 poles) Can be used at 0.3Hz or more at rated 60Hz

1:30 (8, 10 poles) Can be used at 2Hz or more at rated 60Hz

Regeneration:1:12 (2 to 10 poles) Can be used at 5Hz or more at rated 60Hz

DRIVING THE MOTOR

Before operation

Vector

4.3.9 Higher accuracy operation using a motor with encoder (Vector control) (Pr.71, Pr.80, Pr.81, Pr.359, Pr.369, Pr.800)

Full-scale vector control can be performed fitting the FR-A7AP/FR-A7AL (option) and using a motor with encoder. Fast response/high accuracy speed control (zero speed control, servo lock), torque control, and position control can be performed.

• What is vector control?

Excellent control characteristics when compared to V/F control and other control techniques, achieving the control characteristics equal to those of DC machines. It is suitable for applications below.

· To minimize the speed fluctuation even at a severe load fluctuation

· To generate low speed torque

· To prevent machine from damage due to too large torque (torque limit)

· To perform torque control or position control

· Servo-lock torque control which generates a torque at zero speed (i.e. status of motor shaft = stopped)

Vector

Parameter

Number

Name

71 Applied motor

80 Motor capacity

81 Number of motor poles 9999

359

369

Encoder rotation direction

Number of encoder pulses

800 Control method selection

* Use Pr. 178 to Pr. 189 to assign the terminals used for the X18 and MC signal. (Refer to Chapter 4 of the Instruction Manual (Applied).)

Initial Value

9999

1024 0 to 4096

Setting Range Description

0 to 8, 13 to 18, 30,

33, 34, 40, 43, 44,

50, 53, 54

0.4 to 55kW Set the applied motor capacity.

9999 V/F control

2, 4, 6, 8, 10 Set the number of motor poles.

12, 14, 16, 18, 20 X18 signal-ON:V/F control *

9999 V/F control

0 Speed control

1 Torque control

3 Position control

10 to 12

20 V/F control (Advanced magnetic flux vector control)

By selecting a standard motor or constant-torque motor, thermal characteristic and motor constants of each motor are set.

Set 10 + number of motor poles.

Encoder Clockwise direction as viewed from A is forward rotation

Encoder Counter clockwise direction as viewed from A is forward rotation

Set the number of pulses of the encoder. Set the number of pulses before multiplied by four.

MC signal-ON:torque MC signal-OFF:speed

MC signal-ON:position MC signal-OFF:speed

MC signal-ON:torque MC signal-OFF:position

Vector control test operation

(Refer to Chapter 4 of the Instruction Manual (Applied).)

Real sensorless vector control

(Refer to page 64)

CCW

Vector control

Before operation

POINT

If the conditions below are not satisfied, malfunction such as insufficient torque and uneven rotation may occur.

· The motor capacity should be equal to or one rank lower than the inverter capacity.

· Motor to be used is any of Mitsubishi standard motor with encoder (SF-JR 3.7kW or higher), high efficiency motor

with encoder (SF-HR 3.7kW or higher) or Mitsubishi constant torque motor with encoder (SF-JRCA 4P, SF-HRCA

3.7kW or higher) or vector control dedicated motor (SF-V5RU (1500r/min series)). When using a motor other than the above (other manufacturer's motor), perform offline auto tuning without fail.

· Single-motor operation (one motor run by one inverter) should be performed.

· Wiring length from inverter to motor should be within 30m. (Perform offline auto tuning in the state where wiring

work is performed when the wiring length exceeds 30m.)

CAUTION

· Changing the terminal assignment using Pr. 178 to Pr. 189 (input terminal function selection) may affect the other functions. Make setting after confirming the function of each terminal.

· Do not perform vector control with a surge voltage suppression filter (FR-ASF-H/FR-BMF-H) connected.

DRIVING THE MOTOR

Before operation

Speed control is exercised to match the speed command and actual motor speed.

Perform secure wiring. (Refer to page 31.)

Mount the FR-A7AP/FR-A7AL (option).

Set the motor and encoder. (Pr. 71, Pr. 359, Pr. 369)

Set

Pr. 71 Applied motor, Pr. 359 Encoder rotation direction Number of encoder pulses (Refer to page 33.)

Set the motor capacity and the number of motor poles

(Pr. 80, Pr. 81) (Refer to page 66.)

Set the motor capacity (kW) in of motor poles (number of poles) in control is performed when the setting is "9999" (initial value).)

Select a control method. (Refer to page 66.)

Make speed control valid by selecting "0" (speed control), "2" (speedtorque switchover), or "4" (speed-position switchover) for

Set the run command. (Refer to page 85.)

Select the start command and speed command. (1) Start command

according to the motor and encoder used.

Pr. 80 Motor capacity

Pr. 81 Number of motor poles

and

Pr. 369

and set the number

Pr. 800

. (V/F

1)Operation panel: Setting by pressing / of the operation panel

2)External command: Setting by forward rotation or reverse rotation command (terminal STF or STR)

(2)Speed command

Operation panel: Setting by pressing of the operation panel

2)External analog command (terminal 2 or 4) : Give a speed command using the analog signal input to terminal 2 (or terminal 4).

3)Multi-speed command: The external signals (RH, RM, RL) may also be used to give speed command.

Set the torque limit. (Pr. 810)

(Refer to Chapter 4 of the Instruction Manual (Applied).)

Test run

As required

· Perform offline auto tuning. (Pr. 96) (refer to page 71).

· Select online auto tuning. (Pr. 95) (refer to page 76).

· Easy gain tuning (refer to page 77)

· Manual input speed control gain adjustment (refer to page 79)

CAUTION

⋅ Speed command setting range is 0 to 120Hz for vector control. ⋅ The carrier frequencies are selectable among 2k, 6k, 10k, and 14kHz for vector control.

Before operation

z Torque control is exercised to develop torque as set in the torque command. z The motor speed becomes constant when the motor output torque and load torque are balanced.

For torque control, therefore, the speed is determined by the load.

z For torque control, the motor gains speed as the motor output torque becomes greater than the motor load.

To prevent overspeed, set the speed limit value so that the motor speed does not increase too high. (Speed control is exercised during speed limit and torque control is disabled.)

z When speed limit is not set, the speed limit value setting is regarded as 0Hz to disable torque control.

Perform secure wiring. (Refer to page 31.)

Mount the FR-A7AP/FR-A7AL (option).

Set the motor and encoder. (Pr. 71, Pr. 359, Pr. 369)

Set

Pr. 71 Applied motor, Pr. 359 Encoder rotation direction Number of encoder pulses (Refer to page 33.)

Set the motor capacity and the number of motor poles. (Pr. 80, Pr. 81)

(Refer to page 66.)

Set the motor capacity (kW) in of motor poles in (V/F control is performed when the setting is "9999" (initial value).)

Select a control method. (Refer to page 66.)

Set either "1" (torque control), "2" (speed-torque switchover) or "5" (position-torque switchover) in

according to the motor and encoder used.

Pr. 81 Number of motor poles

Pr. 80 Motor capacity

Pr. 800

and make torque control valid.

and set the number

and

Pr. 369

Set the torque command. (Pr. 804)

(Refer to Chapter 4 of the Instruction Manual (Applied).)

Set the speed limit. (Pr. 807)

(Refer to Chapter 4 of the Instruction Manual (Applied).)

Test run

As required

· Perform offline auto tuning. (Pr. 96) (refer to page 71).

· Select online auto tuning. (Pr. 95) (refer to page

· Manual input torque control gain adjustment (refer to Chapter 4 of the Instruction Manual (Applied))

CAUTION

⋅ The carrier frequencies are selectable among 2k, 6k, 10k, and 14kHz for vector control.

76).

DRIVING THE MOTOR

Before operation

z In the position control, the speed command is calculated so that the difference between command pulse (or

parameter setting) and the number of feedback pulses from the encoder is zero to run the motor.

z This inverter can perform simple position feed by contact input, position control by inverter simple pulse input,

and position control by FR-A7AL pulse train input.

Perform secure wiring. (Refer to page 32.)

Mount the FR-A7AP/FR-A7AL (option).

Set the motor and encoder. (Pr. 71, Pr. 359, Pr. 369)

Set

Pr. 71 Applied motor, Pr. 359 Encoder rotation direction Number of encoder pulses (Refer to page 33.)

Set the motor capacity and the number of motor poles.

(Pr. 80, Pr. 81) (Refer to page 66.)

Set the motor capacity (kW) in of motor poles (number of poles) in control is performed when the setting is "9999" (initial value).)

Select a control method. (Refer to page 66.)

Make speed control valid by selecting "3" (position control) "4" (speedposition switchover) or "5" (position-torque switchover) for

according to the motor and encoder used.

Pr. 80 Motor capacity

Pr. 81 Number of motor poles

and set the number

and

Pr. 800

Pr. 369

. (V/F

Selection of position command source. (Pr. 419)

Position command by contact input Set "0" (initial value) in

Setting of parameter for position feed

(Pr. 465 to Pr. 494).

(Refer to Chapter 4 of the Instruction

Manual (Applied).)

Pr. 419

Position command by inverter pulse train input Set "2" in

Selection of command pulse form.

(Refer to Chapter 4 of the Instruction Manual (Applied).)

Pr. 419

(Pr. 428)

Position command from the positioning module of the programmable controller system (through FR-A7AL) Set Pr. 419 = "1"

Refer to the Instruction Manual of FR-A7AL.

Tes t ru n

As required

· Set the electronic gear. (refer to Chapter 4 of the Instruction Manual (Applied))

· Setting of positioning adjustment parameter (refer to Chapter 4 of the Instruction Manual

(Applied))

· Gain adjustment of position control (refer to Chapter 4 of the Instruction Manual (Applied))

CAUTION

⋅ The carrier frequencies are selectable among 2k, 6k, 10k, and 14kHz for vector control.

Before operation

Magnetic flux

Sensorless

Vector

4.3.10 Exhibiting the best performance of the motor performance (offline auto tuning) (Pr. 71, Pr. 83, Pr. 84, Pr. 96)

Magnetic flux

The motor performance can be maximized with offline auto tuning.

• What is offline auto tuning?

When performing Advanced magnetic flux vector control, Real sensorless vector control or vector control, the motor can be run with the optimum operating characteristics by automatically measuring the motor constants (offline auto tuning) even when each motor constants differs, other manufacturer's motor is used, or the wiring length is long. (30m or longer as reference)

Sensorless

Sensorless Vector

Vector

Parameter

Number

Name

71 Applied motor

83 Rated motor voltage 200/400V * 0 to 1000V

84 Rated motor frequency

Auto tuning setting/ status

Initial Value

60Hz 10 to 120Hz Set the rated motor frequency (Hz).

Setting Range Description

0 to 8, 13 to 18,

30, 33, 34, 40,

43, 44, 50, 53, 54

0 Offline auto tuning is not performed

101 Offline auto tuning is performed with motor running

By selecting a standard motor or constant-torque motor, thermal characteristic and motor constants of each motor are set.

Set the rated motor voltage(V). * The initial value differs according to the voltage

level. (200V/400V)

Offline auto tuning is performed without motor running

POINT

· This function is valid only when a value other than "9999" is set in Pr. 80 and Pr. 81 and Advanced magnetic flux

vector control, Real sensorless vector control or vector control is selected.

· You can copy the offline auto tuning data (motor constants) to another inverter with the PU (FR-DU07/FR-PU07).

· Even when motors (other manufacturer's motor, SF-JRC, etc.) other than Mitsubishi standard motor (SF-JR

3.7kW or higher), high efficiency motor (SF-HR 3.7kW or higher), Mitsubishi constant-torque motor (SF-JRCA 4P, SF-HRCA 3.7kW or higher) and vector control dedicated motor (SF-V5RU (1500r/min series)) are used or the wiring length is long (30m or longer as reference), using the offline auto tuning function runs the motor with the optimum operating characteristics.

· Tuning is enabled even when a load is connected to the motor. (As the load is lighter, tuning accuracy is higher.

Tuning accuracy does not change even if the inertia is large.)

· For the offline auto tuning, you can select either the motor non-rotation mode (Pr. 96 = "1") or rotation mode (Pr. 96

= "101").

· The rotation mode has higher tuning accuracy than the non-rotation mode.

· Reading/writing/copy of motor constants tuned by offline auto tuning are enabled.

· The offline auto tuning status can be monitored with the PU (FR-DU07/FR-PU07/FR-PU04).

· Do not use an inverter with a surge voltage suppression filter (FR-ASF-H) connected between the inverter and motor.

DRIVING THE MOTOR

Before operation

(1) Before performing offline auto tuning

Check the following before performing offline auto tuning.

· Make sure Advanced magnetic flux vector control (Pr. 80, Pr. 81), Real sensorless vector control or vector control

(Pr. 800) is selected. (Refer to page 63 )

· A motor should be connected. Note that the motor should be at a stop at a tuning start.

· The motor capacity should be equal to or one rank lower than the inverter capacity.

· Motors such as high-slip motor, high-speed motor and special motor cannot be tuned. (The maximum frequency is

120Hz.)

· Even if tuning is performed without motor running (Pr. 96 Auto tuning setting/status = "1"), the motor may run slightly.

Therefore, fix the motor securely with a mechanical brake, or before tuning, make sure that there will be no problem in safety if the motor runs. (Caution is required especially in vertical lift applications). Note that if the motor runs slightly, tuning performance is unaffected.

· Note the following when selecting offline auto tuning performed with motor running (Pr. 96 Auto tuning setting/status =

"101"). Torque is not enough during tuning. The motor may be run at nearly its rated speed. The mechanical brake is open. No external force is applied to rotate the motor.

· Offline auto tuning will not be performed properly if it is performed with a surge voltage suppression filter (FR-ASF-

H) connected between the inverter and motor. Remove it before starting tuning.

· When exercising vector control, use the encoder that is coupled directly to the motor shaft without looseness.

Speed ratio should be 1:1.

Before operation

(2) Setting

1) Select the Advanced magnetic flux vector control, Real sensorless vector control or vector control.

2) Set "1" or "101" in Pr. 96 Auto tuning setting/status .

· When the setting is "1" . . . . . . . . Tuning is performed without motor running.

It takes approximately 25 to 120s (Excitation noise is produced during tuning.)

*Tuning time differs according to the inverter capacity and motor type.

· When the setting is "101" . . . . . . Tuning is performed with motor running.

It takes approximately 40s until tuning is completed. The motor runs at nearly its rated frequency.

3) Set the rated motor current (initial value is rated inverter current) in Pr. 9 Electronic thermal O/L relay.

4) Set the rated voltage of motor (initial value is 200V/400V) in Pr. 83 Rated motor voltage and rated frequency of motor (initial value is 60Hz) in Pr. 84 Rated motor frequency . (For a Japanese standard motor, etc. which has both 50Hz and 60Hz rated values, set 200V/60Hz or 400V/60Hz).) For vector control dedicated motor SF-V5RU1 / V5RU3 / V5RU4, set as the following table.

Pr. 83 Setting Pr. 84 Setting

SF-V5RU1-30kW or less 160V SF-V5RU1-37kW 170V SF-V5RU3-22kW or less 160V SF-V5RU3-30kW 170V SF-V5RU4-3.7kW, 7.5kW 150V SF-V5RU4-other than the above 160V

* until tuning is completed.

33.33Hz

16.67Hz

REMARKS

· When using the vector control dedicated motor SF-V5RU (1500r/min series) or SF-THY, setting 33 and 34 in Pr. 71 selects

internal constants appropriate for dedicated motors. Therefore, Pr. 83 and Pr. 84 settings are unnecessary.

· Perform auto tuning for SF-V5RU (except for 1500 r/min series) with setting 13 or 14 in Pr. 71 ( For perform auto tuning, set

Pr. 83 and Pr. 84)

· When Pr. 11 DC injection brake operation time = "0" or Pr.12 DC injection brake operation voltage = "0," offline auto tuning is

performed at the initial setting of Pr. 11 or Pr. 12.

· When the positioning control is selected (Pr. 800 = "3" or "5" (when MC signal is OFF)), offline auto tuning is not performed.

5) Set Pr. 71 Applied motor according to the motor used.

Motor Pr. 71 Setting *

Mitsubishi standard motor

Mitsubishi high efficiency motor

Mitsubishi constant-torque motor

Vector control dedicated motor

Other manufacturer's

standard motor

Other manufacturer's

constant-torque motor

* For other settings of Pr. 71, refer to Chapter 4 of the Instruction Manual (Applied).

SF-JR 3

SF-HR 43

Others 3

SF-JRCA 4P 13

SF-HRCA 53

Others (SF-JRC, etc.) 13

SF-V5RU (1500r/min series) SF-THY

SF-V5RU (except for 1500r/min series) 13

−

DRIVING THE MOTOR

Before operation

(3) Execution of tuning

CAUTION

· Before performing tuning, check the monitor display of the operation panel (FR-DU07) or parameter unit (FR-PU04/FRPU07) if the inverter is in the state ready for tuning. (Refer to 2) below) When the start command is turned ON under V/F control, the motor starts.

1)When performing PU operation, press / of the operation panel.

For external operation, turn ON the start command (STF signal or STR signal). Tuning starts.

REMARKS

· The offline auto tuning starts when the inverter start conditions, including the ON status of the MRS signal, are met.

· To force tuning to end, use the MRS or RES signal or press of the operation panel.

(Turning the start signal (STF signal or STR signal) off also ends tuning.)

· During offline auto tuning, only the following I/O signals are valid: (initial value)

· Input signals <valid signal> STOP, OH, MRS, RT, CS, RES, STF, STR

· Output terminal RUN, OL, IPF, FM, AM, A1B1C1 Note that the progress status of offline auto tuning is output in fifteen steps from AM and FM when speed and output frequency are selected.

· Do not perform ON/OFF switching of the second function selection signal (RT) during execution of offline auto tuning. Auto

tuning is not executed properly.

· Setting offline auto tuning (Pr. 96 Auto tuning setting/status = "1 or 101") will make pre-excitation invalid.

CAUTION

· When selecting offline auto tuning performed with motor running (Pr. 96 Auto tuning setting/status = "101"), caution must be taken since the motor runs.

· Since the RUN signal turns on when tuning is started, caution is required especially when a sequence which releases a mechanical brake by the RUN signal has been designed.

· When executing offline auto tuning, input the run command after switching on the main circuit power (R/L1, S/L2, T/L3) of the inverter.

· When Pr.79 = "7," turn ON the X12 signal and select the PU operation mode to perform tuning.

2)Monitor is displayed on the operation panel (FR-DU07) and parameter unit (FR-PU07/FR-PU04) during tuning as below.

Parameter Unit

(FR-PU07/FR-PU04) Display

Pr. 96 setting 1 101 1 101

(1) Setting

(2) Tuning in

progress

(3) Normal end

STOP PU

TUNE

STF

TUNE COMPLETION STF

FWD PU

STOP PU

101

STOP PU

TUNE

102

FWD PU

STF

TUNE COMPLETION

STOP PU

STF

103

(4) Error end (when

the inverter protective function is activated)

TUNE ERROR STF

STOP PU

Operation Panel (FR-DU07) Display

Flickerin

Flickering

· Reference: Offline auto tuning time (when the initial value is set)

Offline Auto Tuning Setting Time

Non-rotation mode (Pr. 96 = "1")

Approximately 25 to 120s (Tuning time differs according to the inverter capacity and motor type.)

Approximately 40s

Rotation mode (Pr. 96 = "101")

(Offline auto tuning time varies with the acceleration and deceleration time settings as indicated below. Offline auto tuning time = acceleration time + deceleration time + approx. 30s)

Before operation

3)When offline auto tuning ends, press of the operation panel during PU operation. For external operation, turn

OFF the start signal (STF signal or STR signal). This operation resets the offline auto tuning and the PU's monitor display returns to the normal indication. (Without this operation, next operation cannot be started.)

REMARKS

· Do not change the Pr. 96 setting after completion of tuning (3 or 103). If the Pr. 96 setting is changed, tuning data is invalid. If the Pr. 96 setting is changed, tuning must be performed again.

4)If offline auto tuning ended in error (see the table below), motor constants are not set. Perform an inverter reset and restart tuning.

Error Display Error Cause Remedy

8 Forced end

9 Inverter protective function operation Make setting again.

Current limit (stall prevention) function was activated.

Converter output voltage reached 75% of rated value.

Calculation error A motor is not connected.

Set "1" or "101" in Pr. 96 and perform tuning again.

Increase acceleration/deceleration time. Set "1" in Pr. 156 .

Check for fluctuation of power supply voltage.

Check the motor wiring and make setting again. Set the rated current of the motor in Pr.9.

5)When tuning is ended forcibly by pressing or turning off the start signal (STF or STR) during tuning, offline

auto tuning does not end properly. (The motor constants have not been set.) Perform an inverter reset and restart tuning.

6)When using the motor corresponding to the following specifications and conditions, reset Pr.9 Electronic thermal O/L relay as below after tuning is completed.

a)When the rated power specifications of the motor is 200/220V (400/440V) 60Hz, set 1.1 times rated motor

current value in Pr.9.

b)When performing motor protection from overheat using a PTC thermistor or motor with temperature detector

such as Klixon, set "0" (motor overheat protection by the inverter is invalid) in Pr.9.

CAUTION

· The motor constants measured once in the offline auto tuning are stored as parameters and their data are held until the offline auto tuning is performed again.

· An instantaneous power failure occurring during tuning will result in a tuning error. After power is restored, the inverter goes into the normal operation mode. Therefore, when STF (STR) signal is on, the motor runs in the forward (reverse) rotation.

· Any alarm occurs during tuning is handled as in the ordinary mode. Note that if a fault retry has been set, retry is ignored.

· The set frequency monitor displayed during the offline auto tuning is 0Hz.

CAUTION

Note that the motor may start running suddenly.

When the offline auto tuning is used in vertical lift application, e.g. a lifter, it may drop due to insufficient torque.

DRIVING THE MOTOR

Before operation

Magnetic flux

Sensorless

Vector

4.3.11 High accuracy operation unaffected by the motor temperature (online auto tuning) (Pr. 95)

Magnetic flux

When online auto tuning is selected under Advanced magnetic flux vector control, Real sensorless vector control or vector control, excellent torque accuracy is provided by temperature compensation even if the secondary resistance value of the motor varies with the rise of the motor temperature.

Sensorless

Sensorless Vector

Vector

Parameter

Number

Name

Online auto tuning selection

Initial Value

Setting Range Description

0 Online auto tuning is not performed

1 Start-time online auto tuning

2 Magnetic flux observer (normal tuning)

(1) Start-time online auto tuning (setting is "1")

· By quickly tuning the motor constants at a start, high accuracy operation unaffected by the motor temperature and stable operation with high torque down to ultra low speed can be performed.

· Make sure Advanced magnetic flux vector control (Pr. 80, Pr. 81 ), Real sensorless vector control or vector control (Pr. 800 ) is selected. (Refer to page 63.)

· Before performing online auto tuning, perform offline auto tuning without fail.

1) Check that "3" or "103" (offline auto tuning completion) is set in Pr. 96 Auto tuning setting/status.

2) Set "1" (start-time online auto tuning) in Pr. 95 Online auto tuning selection.

Online auto tuning is performed from the next starting.

3) When performing PU operation, press / of the operation panel.

For external operation, turn ON the run command (STF signal or STR signal).

CAUTION

· For using start-time online auto tuning in elevator, examine the utilization of a brake sequence for the brake opening timing at a start. Though the tuning ends in about a maximum of 500ms after a start, torque is not provided fully during that period. Therefore, note that there may be a possibility of drop due to gravity.

It is recommended to perform tuning using a start time tuning signal (X28). (Refer to Chapter 4 of the Instruction Manual

(Applied).)

(2) Magnetic flux observer (normal tuning) (setting value is "2")

· When exercising vector control using a motor with encoder, it is effective for torque accuracy improvement. The current flowing in the motor and the inverter output voltage are used to estimate/observe the magnetic flux in the motor. The magnetic flux of the motor is always (including during operation) detected with high accuracy so that an excellent characteristic is provided regardless of the change in the temperature of the secondary resistance.

· Vector control (Pr. 80, Pr. 81, Pr. 800) should be selected. (Refer to page 75.)

CAUTION

· For the SF-V5RU, SF-JR (with encoder), SF-HR (with encoder), SF-JRCA (with encoder) or SF-HRCA (with encoder), it is not necessary to perform offline auto tuning to select adaptive magnetic flux observer. (Note that it is necessary to perform offline auto tuning for the wiring length resistance to be reflected on the control when the wiring length is long (30m or longer as reference).

REMARKS

· Online auto tuning does not operate if the MRS signal is input, if the preset speed is less than the Pr. 13 Starting frequency (V/F control or Advanced magnetic flux vector control), or if the starting conditions of the inverter are not satisfied, e.g. inverter error.

· Online auto tuning does not operate during deceleration or at a restart during DC brake operation.

· Invalid for jog operation.

· Automatic restart after instantaneous power failure overrides when automatic restart after instantaneous power failure is selected. (Start-time online auto tuning is not performed at frequency search.) Perform online auto tuning at a stop with the X28 signal when using automatic restart after instantaneous power failure together.

(Refer to Chapter 4 of the Instruction Manual (Applied) for details.)

· Zero current detection and output current detection are valid during online auto tuning.

· The RUN signal is not output during online auto tuning. The RUN signal turns on at a start.

· If the period from an inverter stop to a restart is within 4s, start-time tuning is performed but the tuning results are not reflected.

Before operation

Sensorless

Vector

4.3.12 To perform high accuracy/fast response operation (gain adjustment of Real sensorless vector control and vector control) (Pr. 818 to Pr. 821, Pr. 880)

Sensorless

Sensorless Vector

Vector

The ratio of the load inertia to the motor inertia (load moment of inertia) is estimated in real time from the torque command and speed during motor operation by vector control. As optimum gain of speed control and position control are automatically set from the load inertia ratio and response level, time and effort of making gain adjustment are reduced. (Easy gain tuning) When the load inertia ratio cannot be estimated due to load fluctuation or Real sensorless vector control is exercised, control gain is automatically set by manually inputting the load inertia ratio. Make a manual input adjustment when vibration, noise or any other unfavorable phenomenon occurs due to large load inertia or gear backlash, for example, or when you want to exhibit the best performance that matches the machine.

Parameter

Number

818

819

Easy gain tuning response level setting

Easy gain tuning selection

820 Speed control P gain 1

821

880

Speed control integral time 1

Load inertia ratio

Name Initial Value Setting Range Description

2 1 to 15

0 Without easy gain tuning

60% 0 to 1000%

0.333s 0 to 20s

7 times 0 to 200 times Set the load inertia ratio to the motor.

2 With load (Pr. 880) manual input, gain calculation

Set the response level. 1: Slow response to 15: Fast response

With load estimation, with gain calculation (valid only during vector control)

Set the proportional gain for speed control. (Increasing the value improves trackability in response to a speed command change and reduces speed variation with disturbance.)

Set the integral time during speed control. (Decrease the value to shorten the time taken for returning to the original speed if speed variation with disturbance occurs.)

(1) Easy gain tuning execution procedure (Pr. 819 = "1" load inertia ratio automatic estimation)

Easy gain tuning (load inertia ratio automatic estimation) is valid only in the speed control or position control mode under vector control. It is invalid under torque control, V/F control, Advanced magnetic flux vector control and Real sensorless vector control.

1) Set the response level using Pr. 818 Easy gain tuning response level setting. Refer to the diagram on the right and set the response level. Increasing the value will improve trackability to the command, but too high value will generate vibration. The relationship between the setting and response level are shown on the right.

Pr. 818 setting

Response level

Guideline of

mechanical resonance

frequency (Hz)

123456789101112131415

Slow response

8 10 12 15 18 22 28 34 42 52 64 79 98 122 150

Large conveyor

Middle

response

General machine tool,

conveyor

Arm robot

Precision

machine tool

Fast

response

DRIVING THE MOTOR

Before operation

2) Each control gain is automatically set from the load inertia ratio estimated during acceleration/deceleration operation and the Pr. 818 Easy gain tuning response level setting value.

Pr. 880 Load inertia ratio is used as the initial value of the load inertia ratio for tuning. Estimated value is set in Pr. 880 during tuning.

The load inertia ratio may not be estimated well, e.g. it takes a long time for estimation, if the following conditions are not satisfied.

· Time taken for acceleration/deceleration to reach 1500r/min is 5s or less.

· Speed is 150r/min or more.

· Acceleration/deceleration torque is 10% or more of the rated torque.

· Abrupt disturbance is not applied during acceleration/deceleration.

· Load inertia ratio is approx. 30 times or less.

· No gear backlash nor belt looseness is found.

3) Press or to estimate the load inertia ratio or calculate gain any time. (The operation command for

external operation is the STF or STR signal.)

(2) Easy gain tuning execution procedure (Pr. 819 = "2" load inertia manual input)

Easy gain tuning (load inertia ratio manual input) is valid only in the speed control mode under Real sensorless vector control or in the speed control or position control mode under vector control.

1) Set the load inertia ratio to the motor in Pr. 880 Load inertia ratio.

2) Set "2" (with easy gain tuning) in Pr. 819 Easy gain tuning selection. Then, Pr. 820 Speed control P gain 1 and Pr. 821 Speed control integral time 1 are automatically set by gain calculation. Operation is performed in a gain adjusted status from the next operation.

3) Perform a test run and set the response level in Pr. 818 Easy gain tuning response level setting. Increasing the value will improve trackability to the command, but too high value will generate vibration. (When "2" (parameter write enabled during operation) is set in Pr. 77 Parameter write selection , response level adjustment can be made during operation.)

REMARKS

· When "1 or 2" is set in Pr. 819 and then returned the Pr. 819 setting to "0" after tuning is executed, tuning results which are set in each parameter remain unchanged.

· When good tuning accuracy is not obtained after executing easy gain tuning due to disturbance and such, perform fine adjustment by manual input. Set "0" (without easy gain tuning) in Pr. 819.

(3) Parameters automatically set by easy gain tuning

The following table indicates the relationship between easy gain tuning function and gain adjustment parameter.

Easy Gain Tuning Selection (Pr. 819) Setting

0 1 2

a) Inertia estimation result (RAM) by

easy gain tuning is displayed.

b) Set the value in the following cases:

• Every hour after power-ON

Load inertia ratio

(Pr. 880)

Speed control P gain 1

(Pr. 820)

Speed control integral time 1

(Pr. 821)

Model speed control gain

(Pr. 828)

Position loop gain

(Pr. 422)

Manual input

• When a value other than "1" is set in Pr. 819

• When vector control is changed to other control (V/F control etc.) using Pr. 800

c) Write is enabled only during a stop

(manual input)

a) Tuning result (RAM) is displayed. a) Gain is calculated when "2" is

b) Set the value in the following cases:

• Every hour after power-on

• When a value other than "1" is set in Pr. 819

• When vector control is changed to other control (V/F control etc.) using Pr. 800

c) Write (manual input) disabled c) Write (manual input) disabled

Manual input

set in Pr. 819 and the result is set in the parameter.

b) When the value is read, the

tuning result (parameter setting value) is displayed.

CAUTION

· Performing easy gain tuning with larger inertia than the specified value during vector control may cause malfunction such as hunting. In addition, when the motor shaft is fixed with servo lock or position control, bearing may be damaged. To prevent these, make gain adjustment by manual input without performing easy gain tuning.

Before operation

(4) Manual input speed control gain adjustment

· Make adjustment when any of such phenomena as unusual machine vibration/noise, low response level and overshoot has occurred.

Proportional gain

200rad/s

120rad/s

60%

(initial value)

100%

Pr. 820

Setting

· The response speed of a motor is equivalent to 120rad/s when Pr.820 Speed control P gain 1 = "60% (initial setting)." Increasing the setting value improves the response level, but setting too large of a gain will produce vibration and/or unusual noise.

· Decreasing the Pr. 821 Speed control integral time 1 shortens the return time taken at a speed change. However, a too short time will generate an overshoot.

· When there is load inertia, the actual speed gain is as given below.

Load fluctuation

Speed

Decreasing the integral time shortens the return time taken.

Actual speed gain = speed gain of motor without load ×

Since increasing the proportional gain enhances the response level and decreases the speed fluctuation.

JM+JL

JM: Inertia of the motor JL: Motor shaft-equivalent load inertia

· Adjustment procedures are as below:

1)Check the conditions and simultaneously change the Pr. 820 value.

2)If you cannot make proper adjustment, change the Pr. 821 value and repeat step 1).

No.

3 Slow response

Phenomenon/

Condition

Load inertia is large

Vibration/noise generated from mechanical system

Long return time (response time)

Overshoot or unstable phenomenon occurs.

Adjustment Method

Set the Pr. 820 and Pr. 821 values a little higher.

Pr. 820

Pr. 821

Set the Pr. 820 value a little lower and the Pr. 821 value a little higher.

Pr. 820

Pr. 821

Set the Pr. 820 value a little higher.

Pr. 820

Set the Pr. 821 value a little lower. Decrease the Pr. 821 value by half until just before an overshoot or the unstable phenomenon does not occur, and set about 0.8 to 0.9 of that value. Set the Pr. 821 value a little higher. Increase the Pr. 821 value double by double until just before an overshoot or the unstable phenomenon does not occur, and set about 0.8 to 0.9 of that value.

When a speed rise is slow, increase the value 10% by 10% until just before vibration/noise is produced, and set about 0.8 to 0.9 of that value. If an overshoot occurs, double the value until an overshoot does not occur, and set about 0.8 to 0.9 of that value.

Decrease the value 10% by 10% until just before vibration/noise is not produced, and set about 0.8 to 0.9 of that value. If an overshoot occurs, double the value until an overshoot does not occur, and set about 0.8 to 0.9 of that value.

When a speed rise is slow, increase the value 5% by 5% until just before vibration/noise is produced, and set about 0.8 to 0.9 of that value.

REMARKS

· When making manual input gain adjustment, set "0" (without easy gain tuning) (initial value) in Pr. 819 Easy gain tuning

selection

DRIVING THE MOTOR

Before operation

(5) When using a multi-pole motor (8 poles or more)

Specially when using a multi-pole motor with more than 8 poles under Real sensorless vector control or vector control, adjust Pr. 820 Speed control P gain 1 and Pr. 824 Torque control P gain 1 according to the motor referring to the following methods.

·For Pr. 820 Speed control P gain 1, increasing the setting value improves the response level, but a too large gain will produce vibration and/or unusual noise.

·For Pr. 824 Torque control P gain 1, note that a too low value will produce current ripples, causing the motor to generate sound synchronizing the cycle of current ripples.

Adjustment method

No. Phenomenon/Condition Adjustment Method

Set a higher value in Pr. 820 Speed control P gain 1 according to the motor inertia.

The motor rotation is unstable in the low

speed range.

2 Speed trackability is poor. Set a higher value in Pr. 820 Speed control P gain 1.

Speed variation at the load fluctuation is

large.

Torque becomes insufficient or torque ripple occurs at starting or in the low

speed range under Real sensorless vector control.

Unusual motor and machine vibration,

noise or overcurrent occurs.

Overcurrent or overspeed (E.OS) occurs

at a start under Real sensorless vector control.

Since the self inertia of a multi-pole motor tends to become large, make adjustment to improve the unstable phenomenon, then make fine adjustment in consideration of the response level using that setting as reference. In addition, when performing vector control with encoder, gain adjustment according to the inertia can be easily done using easy gain tuning (Pr. 819 = 1).

Increase the value 10% by 10% until just before vibration or unusual noise is produced, and set about 0.8 to 0.9 of that value. If you cannot make proper adjustment, increase the value of Pr. 821 Speed control integral time 1 double by double and make adjustment of Pr. 820 again.

Set the speed control gain a little higher. (same as No. 1) If the problem still persists after gain adjustment, increase Pr. 13 Starting frequency or set the acceleration time shorter if the inverter is starting to avoid continuous operation in the ultra low speed range.

Set a lower value in Pr. 824 Torque control P gain 1. Decrease the value 10% by 10% until just before the phenomenon is improved, and set about 0.8 to 0.9 of that value.

(6) Troubleshooting (speed)

Phenomenon Cause Countermeasures

(1) The motor wiring is wrong (1) Wiring check

(2) Encoder specifications (encoder

(3) The encoder wiring is wrong. (3) Check that FWD is displayed when running the motor

Motor does not rotate.

(Vector control)

specification selection switch FR-A7AP/FR-A7AL (option)) are wrong

Before operation

Select V/F control (set "9999" in Pr. 80 or Pr. 81 ) and check the rotation direction of the motor. For the SF-V5RU (1500r/min series), set "160V (320V)" in Pr. 19 Base frequency voltage, and set "50Hz" in Pr. 3 Base frequency.

When the forward rotation signal is input, the motor running in the counterclockwise direction as viewed from the motor shaft is normal. (If it runs in the clockwise direction, the phase sequence of the inverter output side wiring is incorrect.)

(2) Check the encoder specifications.

Check the encoder specifications selection switch (FR-A7AP/FR-A7AL (option)) of differential/ complementary

in the counter-clockwise direction from outside during a stop of the inverter with vector control setting. If REV is displayed, the encoder phase sequence is wrong. Perform the correct wiring or match the Pr. 359 Encoder

rotation direction.

Pr. 359

Setting

Relationship between the Motor

and Encoder

Motor does not run at correct speed. (Speed

command does not match actual speed)

Speed does not rise to the

speed command.

(4) The Pr. 369 Number of encoder

pulses setting and the number of encoder used are different.

(5) Encoder power specifications

are wrong. Or, power is not input.

(1) The speed command from the

command device is incorrect. The speed command is compounded with noise.

(2) The speed command value

does not match the inverterrecognized value.

(3) The number of encoder pulses

setting is incorrect.

(1) Insufficient torque.

Torque limit is actuated.

(2) Only P (proportional) control is

selected.

(Initial value)

(4) The motor will not run if the parameter setting is

smaller than the number of encoder pulses used. Set the Pr. 369 Number of encoder pulses correctly.

(5) Check the power specifications (5V/12V/15V/24V) of

encoder and input the external power supply.

(1) Check that a correct speed command comes from the

command device. Decrease Pr. 72 PWM frequency selection.

(2) Readjust speed command bias/gain Pr. 125, Pr. 126, C2

to C7 and C12 to C15.

(3) Check the setting of Pr. 369 Number of encoder pulses.

(vector control)

(1) -1 Increase the torque limit value.

(Refer to torque limit of speed control on Chapter 4

of the Instruction Manual (Applied) )

(1) -2 Insufficient capacity

(2) When the load is heavy, speed deviation will occur

under P (proportional) control. Select PI control.

Encoder Clockwise direction as viewed from A is forward rotation

Encoder Counter clockwise direction as viewed from A is forward rotation

CCW

DRIVING THE MOTOR

Before operation

Phenomenon Cause Countermeasures

4 Motor speed is unstable.

Motor or machine hunts

(vibration/noise is produced).

Acceleration/deceleration

time does not match the setting.

Machine operation is

unstable.

Speed fluctuates at low

speed.

(1) The speed command varies. (1) -1 Check that a correct speed command comes from

the command device. (Take measures against

noises.) (1) -2 Decrease Pr. 72 PWM frequency selection. (1) -3 Increase

(2) Insufficient torque. (2) Increase the torque limit value.

(Refer to torque limit of speed control on

(3) The speed control gains do not

match the machine. (mechanical resonance)

(1) The speed control gain is high. (1) -1 Perform easy gain tuning. (Refer to page 77)

(2) The torque control gain is high. (2) Decrease the Pr. 824 value.

(3) The motor wiring is wrong. (3) Check the wiring

(1) Insufficient torque. (1) -1 Increase the torque limit value.

(2) Large load inertia. (2) Set the acceleration/deceleration time that meets the

(1) The speed control gains do not

match the machine.

(2) Slow response because of

improper acceleration/ deceleration time of the inverter.

(1) Adverse effect of high carrier

frequency.

(2) Low speed control gain. (2) Increase Pr. 820 Speed control P gain 1.

(3) -1 Perform easy gain tuning. (Refer to page 77 ) (3) -2 Adjust Pr. 820, Pr. 821. (Refer to page 79) (3) -3 Perform speed feed forward/model adaptive speed

control.

(1) -2 Decrease Pr. 820 and increase Pr. 821. (1) -3 Perform speed feed forward control and model

adaptive speed control.

(Refer to torque limit of speed control on

(1) -2 Perform speed feed forward control.

load.

(1) -1 Perform easy gain tuning. (Refer to page 77) (1) -2 Adjust Pr. 820, Pr. 821. (Refer to page 79) (1) -3 Perform speed feed forward control and model

adaptive speed control.

(2) Change the acceleration/deceleration time to an

optimum value.

(1) Decrease Pr. 72 PWM frequency selection.

Pr. 822 Speed setting filter 1. (Refer to Chapter 4 of

the Instruction Manual (Applied) )

the Instruction Manual (Applied

) )

Chapter 4 of

Start/stop from the operation panel (PU

operation mode)

4.4 Start/stop from the operation panel (PU operation mode)

POINT

From where is the frequency command given?

Operation at the frequency set in the frequency setting mode of the operation panel →Refer to 4.4.1 (Refer to page 83)

· Operation using the setting dial as the potentiometer →Refer to 4.4.2 (Refer to page 85)

· Change of frequency with ON/OFF switches connected to terminals →Refer to 4.4.3 (Refer to page 86)

· Frequency setting with a voltage output device →Refer to 4.4.4 (Refer to page 88)

· Frequency setting with a current output device →Refer to 4.4.5 (Refer to page 90)

4.4.1 Setting the set frequency to operate (example: performing operation at 30Hz)

POINT

Operation panel (FR-DU07) is used to give both of frequency and start commands in PU operation.

Operation panel

(FR-DU07)

Operation example

Performing operation at 30Hz.

Operation

1.Screen at power-ON

The monitor display appears.

2.Press to choose the PU

operation mode.

3.Turn to show the frequency " "

(30.00Hz) you want to set. The frequency flickers for about 5s.

4.While the value is flickering,

press to set the frequency.

If you do not press , the value flickers for about 5s

and the display then returns to " " (0.00Hz). At this time, return to "Step 3" and set the frequency again. After the value flickered for about 3s,

the display returns to " " (monitor display).

5.Start acceleration constant speed

Press or to start running.

The frequency on the display increases

in Pr.7 Acceleration time, and " "

(30.00Hz) appears.

Display

PU indicator is lit.

Flickers for

about 5s

Flicker ··· Frequency setting complete!!

After 3s, the monitor display appears.

6.To change the set frequency, perform the operation in above steps 3 and 4.

(Starting from the previously set frequency.)

7.Deceleration Stop

Press to stop.

The frequency on the display decreases in Pr. 8 Deceleration time, and the motor stops rotating with " " (0.00Hz) displayed.

Stop

DRIVING THE MOTOR

Start/stop from the operation panel (PU

operation mode)

Operation cannot be performed at the set frequency ... Why?

Did you carry out step 4 within 5s after step 3? (Did you press within 5s after turning ?)

The frequency does not change by turning ... Why?

Check to see if the operation mode selected is External operation mode. (Press to change to PU operation mode.)

Operation does not change to the PU operation mode ... Why?

Check that "0" (initial value) is set in Pr. 79 Operation mode selection.

Check that the start command is not on. Change acceleration time Pr. 7 (Refer to page 61) Change deceleration time Pr. 8 (Refer to page 61)

For example, limit the motor speed to 60Hz maximum. Set "60Hz" in Pr. 1. (Refer to page 60)

REMARKS

· Press to show the set frequency.

· can also be used like a potentiometer to perform operation. (Refer to page 85)

Start/stop from the operation panel (PU

4.4.2 Use the setting dial like a potentiometer to perform operation.

POINT

Set "1" (setting dial potentiometer mode) in Pr. 161 Frequency setting/key lock operation selection.

Operation example Change the frequency from 0Hz to 60Hz during operation

DisplayOperation

1. Screen at power-ON

The monitor display appears.

operation mode)

2. Press to choose PU operation mode.

PU indicator is lit.

3. Change Pr. 161 to the setting value " ".

(Refer to page 52 for change of the setting.)

4.Press (or ) to start the inverter.

5.Turn until " " appears.

The flickering frequency is the set frequency.

You need not press .

REMARKS

· If flickering "60.00" turns to "0.0", the Pr. 161 Frequency setting/key lock operation selection setting may not be "1".

· Independently of whether the inverter is running or at a stop, the frequency can be set by merely turning .

CAUTION

· When using setting dial, the frequency goes up to the set value of Pr. 1 Maximum frequency (initial value is 120Hz). Adjust Pr. 1 Maximum frequency setting according to the application.

The frequency flickers for about 5s.

DRIVING THE MOTOR

Start/stop from the operation panel (PU

Turn until (

Turn to change it to the

setting value " ".

operation mode)

4.4.3 Setting the frequency by switches (three-speed setting)

POINT

· Use the operation panel (FR-DU07) ( or ) to give a start command.

· Switch ON the RH, RM, or RL signal to give a frequency command. (Three-speed setting)

· Set "4" (External/PU combined operation mode 2) in Pr. 79 Operation mode selection.

[Connection diagram]

Inverter

High speed Middle speed Low speed

Operation example

RH RM RL SD

Operation at low speed (10Hz)

1. Screen at power-ON

The monitor display appears.

2. Press to choose the parameter setting

mode.

Pr. 79) appears.

Operation panel

(FR-DU07)

Speed 1

(High speed)

Speed 2 (Middle speed)

Output frequency (Hz)

DisplayOperation

The parameter number read previously appears.

Speed 3 (Low speed)

4. Press to read the present set value.

" "(initial value) appears.

6. Press to set.

7. Mode/monitor check

Press twice to change to monitor / frequency monitor. [PU] indicator and [EXT] indicator are lit.

8. Start

Turn ON the low-speed switch (RL).

Flicker ··· Parameter setting complete!!

Low speed

High speed

Middle speed

Start/stop from the operation panel (PU

Operation Display

operation mode)

9. Acceleration constant speed

Press or to start running.

The frequency on the display increases

in Pr.7 Acceleration time, and " "

(10.00Hz) appears.

10.Deceleration

Press to stop. The frequency on the display decreases in Pr. 8 Deceleration time, and the motor stops rotating with " " (0.00Hz) displayed.

11. STOP

Turn OFF the low-speed switch (RL).

60Hz for the RH, 30Hz for the RM and 10Hz for the RL are not output when they are turned ON ... Why?

Check for the setting of Pr. 4, Pr. 5, and Pr. 6 once again. Check for the setting of Pr. 1 Maximum frequency and Pr. 2 Minimum frequency once again.

(Refer to page 60.) Check that Pr. 180 RL terminal function selection = "0", Pr. 181 RM terminal function selection = "1", Pr.

182 RH terminal function selection = "2" and Pr. 59 Remote function selection = "0". (all are initial values)

[FWD (or REV)] lamp is not lit ... Why?

Check that wiring is correct. Check the wiring once again. Check for the Pr. 79 setting once again. (Pr. 79 must be set to "4".)

(Refer to page 62.)

Change the frequency of the terminals RL, RM, and RH. ... How?

Refer to page 94 to change the running frequency at each terminal in Pr. 4 Multi-speed setting (high speed), Pr. 5 Multi-speed setting (middle speed), and Pr. 6 Multi-speed setting (low speed).

High speed

Middle speed

Low speed

OFF

Stop

REMARKS

· Initial values of terminals RH, RM, and RL are 60Hz, 30Hz, and 10Hz. (To change, set Pr. 4, Pr. 5, and Pr. 6.)

· In the initial setting, when two or more of multi-speed settings are simultaneously selected, priority is given to the set frequency

of the lower signal. For example, when RH and RM signals turn ON, RM signal (Pr. 5) has a higher priority.

· Maximum of 15-speed operation can be performed.

(Refer to the Chapter 4 of the Instruction Manual (Applied).)

DRIVING THE MOTOR

Start/stop from the operation panel (PU

Turn until (

Turn to change it to

the setting value " ".

operation mode)

4.4.4 Setting the frequency by analog input (voltage input)

POINT

· Use the operation panel (FR-DU07) ( or ) to give a start command.

· Use the (frequency setting) potentiometer to give a frequency command. (Connect terminals 2 and 5 to input a voltage.)

· Set "4" (External/PU combined operation mode 2) in Pr. 79 Operation mode selection.

[Connection diagram] (The inverter supplies 5V of power to the frequency setting potentiometer.(Terminal 10)

Inverter

Operation panel

Frequency setting potentiometer

Operation example Performing operation at 60Hz.

2 5

(FR-DU07)

)

1. Screen at powe-ON

The monitor display appears.

2. Press to choose the parameter setting

mode.

Pr. 79) appears.

4. Press to read the present set value.

" "(initial value) appears.

6. Press to set.

7. Mode/monitor check

Press twice to choose the monitor/frequency monitor. [PU] indicator and [EXT] indicator are lit.

DisplayOperation

The parameter number read previously appears.

Flicker ··· Parameter setting complete!!

8. Start

Press or . [FWD] or [REV] is flickering as no frequency command is given.

9. Acceleration → constant speed

Turn the potentiometer (frequency setting potentiometer) clockwise slowly to full. The frequency value on the display

increases in Pr. 7 Acceleration time, and " "(60Hz) appears.

Flickering

Start/stop from the operation panel (PU

DisplayOperation

Deceleration

10.

Turn the potentiometer (frequency setting potentiometer) counterclockwise slowly to full. The frequency on the display decreases in Pr. 8 Deceleration time, and the motor stops rotating with " " (0.00Hz) displayed. [FWD] indicator or [REV] indicator flickers.

Stop

11. Stop

Press .

indicator

[FWD]

Change the frequency (60Hz) of the maximum value of potentiometer (at 5V, initial value)

Adjust the frequency in Pr. 125 Terminal 2 frequency setting gain frequency. (Refer to page 97.)

Change the frequency (0Hz) of the minimum value of potentiometer (at 0V, initial value)

Adjust the frequency in calibration parameter C2 Terminal 2 frequency setting bias frequency. (Refer to

Chapter 4 of the Instruction Manual (Applied).)

or [REV] indicator turns OFF.

operation mode)

Flickering

DRIVING THE MOTOR

Start/stop from the operation panel (PU

Turn until (

Turn to change it to the setting

alue "

operation mode)

4.4.5 Setting the frequency by analog input (current input)

POINT

· Use the operation panel (FR-DU07) ( or ) to give a start command.

· Input a current to give a frequency command. (Connect terminals 4 and 5 to input a current.)

· Switch ON the AU signal.

· Set "4" (External/PU combined operation mode 2) in Pr. 79 Operation mode selection.

[Connection diagram]

Inverter

AU signal

Current signal

source

(4 to 20mADC)

Operation example Performing operation at 60Hz.

4 (+)

5 (-)

Operation panel

(FR-DU07)

DisplayOperation

Screen at power-ON The monitor display appears.

Press to choose the parameter setting mode.

Press to read the present set value. " "(initial value) appears.

Pr. 79) appears.

Press to set.

Mode/monitor check Press twice to choose the monitor/frequency monitor. [PU] indicator and [EXT] indicator are lit.

Start Check that the terminal 4 input selection signal (AU) is on. Press or . [FWD] or [REV] is flickering as no frequency command is given.

The parameter number read previously appears.

Flicker ··· Parameter setting complete!!

Flickering

Start/stop from the operation panel (PU

operation mode)

DisplayOperation

Acceleration → constant speed Perform 20mA input. The frequency on the display increases in Pr. 7 Acceleration time and appears.

10.

Deceleration Input 4mA or less.

The frequency on the in Pr. 8 Deceleration time, and the motor stops rotating with " " (0.00Hz) displayed.

[FWD] indicator or [EXT] indicator flickers.

11.

Stop Press . [FWD] indicator or [REV] indicator turns OFF.

" " (

display

60.00Hz)

decreases

REMARKS

Pr. 184 AU terminal function selection must be set to "4" (AU signal) (initial value). (Refer to Chapter 4 of the Instruction Manual (Applied).)

Current signal

source

(20mADC)

Current signal

source

(4mADC)

Stop

Flickering

Change the frequency (60Hz) at the maximum value of potentiometer (at 20mA, initial value)

Adjust the frequency in Pr. 126 Terminal 4 frequency setting gain frequency. (Refer to page 99.)

Change the frequency (0Hz) at the minimum value of potentiometer (at 4mA, initial value)

Adjust the frequency in calibration parameter C5 Terminal 4 frequency setting bias frequency. (Refer to

Chapter 4 of the Instruction Manual (Applied).)

DRIVING THE MOTOR

Start and stop using terminals (External

Turn until (

Turn to change it to the

operation)

4.5 Start and stop using terminals (External operation)

POINT

From where is the frequency command given?

· Operation at the frequency set in the frequency setting mode of the operation panel → Refer to 4.5.1(Refer to page 92)

· Give a frequency command by switch (multi-speed setting) → Refer to 4.5.2 (Refer to page 94)

· Perform frequency setting by a voltage output device → Refer to 4.5.3 (Refer to page 96)

· Perform frequency setting by a current output device → Refer to 4.5.5 (Refer to page 98)

4.5.1 Setting the frequency by the operation panel (Pr. 79 = 3)

POINT

· Switch ON the STF(STR) signal to give a start command.

· Use the operation panel (FR-DU07) ( ) to give a frequency command.

· Set “3” (External/PU combined operation mode 1) in Pr. 79 Operation mode selection.

[Connection diagram]

Inverter

Forward rotation start

Reverse rotation start

Operation example

Performing operation at 30Hz.

Operation

1.Screen at power-ON

The monitor display appears.

2.Press to choose the PU

operation mode.

3.Press to choose the parameter

setting mode.

Pr. 79) appears.

STF STR

Operation panel

(FR-DU07)

Display

PU indicator is lit.

The parameter number read previously appears.

5.Press to read the present set value.

" "(initial value) appears.

setting value "

7.Press to set.

Flicker ··· Parameter setting complete!!

8. Mode/monitor check

Press twice to choose the monitor/frequency monitor. [PU] indicator and [EXT] indicator are lit.

Start and stop using terminals (External

operation)

Operation

9. Turn to show the selected

frequency, " " (30.00Hz).

The frequency flickers for about 5s.

10.While the value is flickering,

press to set the frequency.

If you do not press ,the value flickers for about 5s and the display then returns to (display) Hz. At this time, return to "Step 8" and set the frequency again.

After about 3s of flickering of the value,

the display goes back to " " (monitor display).

11.Start acceleration constant speed

Turn ON the start switch (STF or STR). The frequency on the display increases in Pr.7 Acceleration time, and " " (30.00Hz) appears. [FWD] indicator is lit during forward rotation, and [REV] indicator is lit during reverse rotation.

CAUTION

When both of STF and STR signals are turned ON, the motor cannot start. If both are turned ON while the motor is running, the motor decelerates to a stop.

Forward rotation

Display

Flickers for about 5s

Flicker ··· Frequency setting complete!!

After 3s, the monitor display appears.

Reverse rotation

12.To change the set frequency, perform the operation in above steps 9 and 10.

(Starting from the previously set frequency.)

OFF

Forward rotation

Reverse rotation

Stop

13.Deceleration Stop

Turn OFF the start switch (STF or STR). The frequency on the display decreases in Pr. 8 Deceleration time, and the motor stops rotating with " " (0.00Hz) displayed.

REMARKS

· Pr. 178 STF terminal function selection must be set to "60" (or Pr. 179 STR terminal function selection must be set to "61"). (all are initial values)

· When Pr. 79 Operation mode selection is set to "3", multi-speed operation (refer to page 94) is also valid.

When the inverter is stopped by of the operation panel (FR-DU07), and are

displayed alternately.

1. Turn the start switch (STF or STR) OFF.

2. The display can be reset by .

Flickering

DRIVING THE MOTOR

Mitsubishi Electronics FR-A701 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

This section is specifically about safety matters

1 OUTLINE

1.1 Product checking and parts identification

1.2 Inverter and peripheral devices

1.2.1 Peripheral devices

1.3 Method of removal and reinstallation of the front cover

1.4 Installation of the inverter and enclosure design

1.4.1 Inverter installation environment

1.4.2 Cooling system types for inverter enclosure

1.4.3 Inverter placement

2 WIRING

2.1 Terminal connection diagram

2.2 Main circuit terminal specifications

2.2.1 Specification of main circuit terminal

2.2.2 Terminal arrangement of the main circuit terminal, power supply and the motor wiring

2.2.3 Cables and wiring length

2.2.4 When connecting the control circuit and the main circuit separately to the power supply

2.3 Control circuit specifications

2.3.1 Control circuit terminals

2.3.2 Changing the control logic

2.3.3 Control circuit terminal layout

2.3.4 Wiring instructions

2.3.5 When connecting the operation panel using a connection cable

2.3.6 RS-485 terminal block

2.3.7 Communication operation

2.3.8 USB connector

2.4 Connection of motor with encoder (vector control)

3 PRECAUTIONS FOR USE OF THE INVERTER

3.1 EMC and leakage currents

3.1.1 Leakage currents and countermeasures

3.1.2 EMC measures

3.1.3 Power supply harmonics

3.1.4 Harmonic suppression guideline

3.2 Power-off and magnetic contactor (MC)

3.3 Inverter-driven 400V class motor

3.4 Precautions for use of the inverter

3.5 Failsafe of the system which uses the inverter

4 DRIVING THE MOTOR

4.1 Step of operation

4.2 Operation panel (FR-DU07)

4.2.1 Parts of the operation panel (FR-DU07)

4.2.2 Basic operation (factory setting)

4.2.3 Operation lock (Press [MODE] for an extended time (2s))

4.2.4 Monitoring of output current and output voltage

4.2.5 First priority monitor

4.2.6 Setting dial push

4.2.7 Changing the parameter setting value

4.2.8 Parameter clear, all parameter clear

4.2.9 Parameter copy and parameter verification

4.3 Before operation

4.3.1 Simple mode parameter list

4.3.2 Overheat protection of the motor by the inverter (Pr. 9)

4.3.3 When the rated motor frequency is 50Hz (Pr. 3)

4.3.4 Increase the starting torque (Pr. 0)

4.3.5 Limit the maximum and minimum output frequency (Pr. 1, Pr. 2)

4.3.6 Change acceleration and deceleration time (Pr. 7, Pr. 8)

4.3.7 Selection of the start command and frequency command locations (Pr. 79)

4.3.8 Large starting torque and low speed torque are necessary (Advanced magnetic flux vector control, Real sensorless vector control) (Pr. 71, Pr. 80, Pr. 81, Pr. 800)

4.3.9 Higher accuracy operation using a motor with encoder (Vector control) (Pr.71, Pr.80, Pr.81, Pr.359, Pr.369, Pr.800)

4.3.10 Exhibiting the best performance of the motor performance (offline auto tuning) (Pr. 71, Pr. 83, Pr. 84, Pr. 96)

4.3.11 High accuracy operation unaffected by the motor temperature (online auto tuning) (Pr. 95)

4.3.12 To perform high accuracy/fast response operation (gain adjustment of Real sensorless vector control and vector control) (Pr. 818 to Pr. 821, Pr. 880)

4.4 Start/stop from the operation panel (PU operation mode)

4.4.1 Setting the set frequency to operate (example: performing operation at 30Hz)

4.4.2 Use the setting dial like a potentiometer to perform operation.

4.4.3 Setting the frequency by switches (three-speed setting)

4.4.4 Setting the frequency by analog input (voltage input)

4.4.5 Setting the frequency by analog input (current input)

4.5 Start and stop using terminals (External operation)

4.5.1 Setting the frequency by the operation panel (Pr. 79 = 3)