Mitsubishi Electric Freqrol Z024-UL Instruction Manual
MITSUBISHI
VVVF TRANSISTOR INVERTER
-
INSTRUCTION MANUAL
-
0
MlTSUBlSHl
A
ELECTRIC
.- .
Introduction
Thank you for your purchase of MiBubishi Micro-Inverter
FREQROL-2024-UL.
Before operating the inverter, read this manual carefully. Please deliver
this
instruction manual
to
the
actual
user
of
the inverter.
CONTENTS
Instructions
1
.
Precautions
......................................................................................................
1
2
.
Block Diagram and Description
......................................................................
7
3
.
Preparation before Operation
.........................................................................
11
4 . Apparatus and Components
to
be Prepared before Operation
....................
13
5
.
Installation
.......................................................................................................
15
6
.
Wiring
...............................................................................................................
17
7
.
Pre-Operation Settings
...................................................................................
26
8
.
Operation
.........................................................................................................
30
9
.
Using the Parameter Unit
...............................................................................
38
10
.
Parameter Unit Installation
.............................................................................
40
11 . Outline
of
Parameter Unit Functions
..............................................................
42
12
.
Operation
.........................................................................................................
43
Selecting operation mode
...............................................................................
43
Operating the motor with the parameter unit
.................................................
46
Settings
of
control variables (Parameters)
....................................................
51
Monitor
.............................................................................................................
55
Frequency meter calibration
...........................................................................
64
Adjusting bias and gain for frequency reference signal
................................
66
Cautions for
PU
operation
..............................................................................
69
13
.
Details
of
Each Parameter
..............................................................................
72
14 .
Maintenance and Inspection
...........................................................................
102
15
.
Troubleshooting
..............................................................................................
109
16 . Specifications
................................................................................................
113
17
.
DIMENSIONS
..................................................................................................
127
18
.
Selection of Peripheral Devices
.....................................................................
133
I
Handling Instructions
I
BUR
.
Improper use and operation may cause malfunction of the inverter
or
considerable reduction in service
life. In an extreme case, the inverter might be damaged. Handle the unit correctly, following
-'
descriptions and notes in each section
of
this manual.
P.113
Power Supply Speclflcatlon
Use
the
inverter within
its
allowable power supply range.
Power supply
~ ~~
Instructlons
I
Refer
to:
I
Fuses
Circuit
Breaker
Magnetic
contactor
(MC)
I
I
I
Power factor
improving
AC
reactor
(FR-BAL)
Ill
lnstallatlon
of
Reactor
For power factor improvement, or when installing the
wiring distance of
10
m
or
shorter,
use
of a reactor
is
recommended. Choose a reactor according
to
the
inverter
model and size.
Ill
Handling Instructions
A
til
installation Location
The service life
of
the inverter depends
on
ambient
temperature. Ambient temperature should
be
as low as
possible,
so
that the allowable range may
not
be exceeded.
When housing the inverter in an enclosure, this point
should be considered.
Wirlng
Miswiring might cause damage
to
the inverter. Keep a
sufficient distance between the control signal lines and the
main circuit
so
as
not
to
cause
noise
interference.
p.9,,
5,,6
P.9,20
designed)
to
the
output.
Use
of
such equipment may cause damage
to
either inverter or the
Grounding
Motor
Ground the motor securely
1.
PRECAUTIONS
Use
the Inverter wlthln the allowable ambient temperature range.
The service life of the inverter depends on ambient temperature.
Ambient temperature should be as low as possible, such that the
allowable range is not exceeded. Care should be taken for installation
direction and the environment.
(See page
1516.)
--
FREQROL
Do
not perform Inverter contlnulty test.
When measuring isolation resistance
of
power line or motor, disconnect
Motor
connections
to
the inverter
or
short-circuit across terminals as follows.Pow
Do
not perform a continuity test on the control circuit.
Conlinuily Continuity
tester tester
If
power
voltage
Is
applied to the output circuit
of
the Inverter, it will
be damaged.
damaged. Check to ensure that wiring and operation sequence (such as
If
the power voltage is applied to terminals
U,
V,
W,
the inverter will be
commercial power source selector circuit) are correct.
Do
not supply a
voltage exceeding the allowable voltage range.
-1-
I.
0N.OFFI
oN’oFF+.,ON.OFF!
Do
not use the magnetic contactor at the power supply side to
start or stop the motor (or the inverter).
Repeated magnetic contactor switching for startktop may cause
supply
Po~~~n
Magnetic
inverter failure.
contactor
A
The inverter has dangerous high voltage circuits. When checking
indicator (commonly used as an electric charge indicator) is off.
Do
not connect a power capacltor
or
surge suppressor on the
(MC)
Do
not access the inside
of
the inverter during operatlon.
Power indicator lamp
the inverter, disconnect the power supply and ensure that the power
\ /
/\
charge
exisIs.
When
the
indicator
output circuit
of
the inverter.
I
Such installation might cause inverter trip or damage to the
capacitor or surge suppressor.
If
such a device is connected,
remove it.
The inverter output and input circuits (main circuits) contain high
frequency harmonics that may cause interference with
communication equipment
(AM
radios).
If
so,
use of a noise filter FR-BIF (only for input circuit) or a
line noise filter FR-BLF help to reduce the effects of noise.
Please contact your mitsubishi supplier for additional information.
r
About Radio Nolse
I
M
PORT ANT
COVER
Power must be removed for at least 3 minutes, before removing any covers.
Removal
of
any covers exposes the operator to live terminals.
Please ensure power supply is removed.
-2-
PRECAUTIONS ON USE
Parsmetar number
20
39
Carefully read the entire instruction manual.
Panmeter name
Frequency
for
5
V
input
Frequency
for
20
rnA
input
Control varlabie at shipment
‘60.5-63
HZ
.
1.
These parameters refer to maximum frequency when the Inverter is supplied.
When the inverter is supplied, the inverter output frequency is 60 Hz when the external frequency
reference signal is DC
5
V
(1OV)
or
20
mA.
However, parameters (see below) that set the
maximum output frequency have a set value over
60
Hz.
‘
The parameter at shipment
(60
Hz) that appears
on
pages 69,70 and 71 of this instruction
manual should be interpreted to
be
the above.
Note:
To
adjust the relationship between the frequency reference signal and output frequency, follow the
setting procedures described on page
29
of this instruction manual.
-3-
~~
Inverter
r
(
/’
Frequency reference potentiometer
(voltage signal)
Pr.20
(>
10
2
(0-5Vor0-10
V)
common
,.
5
Frequency reference signal
(current signal)
Pr.39
(
/’
(>
10
2
(0-5Vor0-10
V)
common
,.
5
-b4
(4-20mA)
-4-
I
2.
Operation of the Parameter Unit When
Using
the Output shutoff Function
When using the parameter unit in the external signal operation mode, pressing the
PU OP
key on
the parameter unit
cannot
select the
PU
operation mode
if
the output shutoff signal (MRS
terminal) and start signal (STF or STR terminal) are in the following conditions.
1.
After the operator turned the output shutoff signal
ON
while the start signal was
ON,
the oper-
ator has turned off the start signal alone.
Start sianal
.....
I
1
OFF
across terminals STF (STR) and
SD
OutDut shutoff sianal
.....
'across terminals MRS and
SD
In
2.
In the condition that the output shutoff signal alone was
ON,
the operator turned the start sig-
nal from
ON
to OFF.
EF
Start signal
.....
Output shutoff signal
.....
across terminals STF (STR) and
SD
across terminals MRS and
SD
-5-
To
select the
PU
operation
mode:
First, break connection between terminals
MRS
and
SD,
then press the
PU
OP
key.
Note: When the operator has changed the function of terminal
MRS
from ’output shutoff’ to ’second
3.
Attachlng the Front Cover
accelerationldeceleration
time selection’, it is possible to select the
PU
operation mode on the
condition that the start signal is
OFF.
When
attaching the front cover, locate the lower lugs first, into the main cover.
Bring the upper part
of
front cover to the main cover and press firmly.
it will “click” when in the correct position.
-6-
2.
Block Diagram and Description
Front cover
To
remove
the
front cover, press
the latch and
ease the cover
forward.
Name plate
The
name plate
shows
type
of
series and
capacity
in
kW
(See
next page.)
k.
Front cover
Remove this cover
to
expose the terminal
block.
Power
be
removed.
/
mounted
in
its place
w
Mounting
hole
(four positions)
The inverter type, capacity,
etc. are on the rating plate.
supvlied. an accessory cover
is
-7-
2.
Block
Diagram
and
Description
0.1
K
to
3.7K
Model
Size
Inverter
capacity
is
shown
in
kW.
FR-2024-
3.7K
T
I
Applicable
motor
caeacltv
Symbol
-8-
Inverter
wlth the
Front
Cover
Removed
I
1
Power indicator
I
lam0 (POWER)
The parameter unit or
connection cable is
connected through this
Lights up when power is
supplied. (Commonly
used for indicating
capacitor charge.)
11
Lights up when the
protective circuit is
activated.
connector.
Signals such as the start and
frequency reference signals are
transmitted through connections
to this terminal block.
Terminal block for
power supply and (page
20)
motor
J
The
input power source and
motor are connected to this
front cover
1
(two
positions)
-9-
How
to Remove the Front Cover
While pressing the removal latch(s) at the top of the front cover, ease the cover forward to remove
it.
To
attach the front cover, insert the lugs (two positions) at the bottom
of
of the front cover into
the sockets at the chassis bottom and press the cover against the chassis.
\
Press the latch
(8)
Ease the cover
Front cover
b
<CAUTION>
Chassis
Lug
(two
positions)
Do
not remove the chassis from the body or the inverter will be
damaged.
-10-
I
3.
PreDaration before Operation
1.
Unpacking and Checking the Product
After unpackina the inverter, check the
rating plate at-the right side of the in-
verter to make sure that the model and
rating meet your order.
Also
check that
the inverter has not been damaged.
.
Accessories, Instruction Manual
n
2.
Preparation of Apparatus and Components Needed for Operation
Apparatus and Components
to
be prepared differ depending on how you operate the inverter. Prepare necessary
components referring
to
operation meth-
ods on page
13.
(Next page)
Applicable
motor
capacity
1-
INVERTER
Type
MlTSUBlSHl
7
MODEL
FR-2024-0.75K-UL
Input
POWER
1
HP
AC
INPUT
3HP 2OOV-230V
50/60Hz
OUTPUT
5A max 200-230V
SERIAL
0151
TC100A08
1051
output
ratina
1
AMITSUBISHI
ELECTRIC
CORPORATION
MADE
IN
JAP~N
I3
-11
-
stallation location, installation direction, and
surrounding space
so
as not
to
cause a re-
duction in the inverter service life or perfor-
mance.
~~ ~
4.
Wiring
Connect the power source, motor, and oper-
ation signal (control signals)
to
the terminal
block. Improper wiring may cause damage
to
the inverter.
-12-
Mode
Connection
Example
Notes
External signal opemtlon
Inverter
!
PU
i
I.
A
start signal and a frequency reference signal are
required
to
run the inverter.
2.
Connection of the parameter unit allows for
PU
opera-
tion, as well.
PU
opsrrtlon
Inverter
FR-Z024
Parameter
unit
r"":
:q
p"
.I
,I
L.--..l
I.
See
page
30
for parameter
unit operating procedures.
?.
When
the
inverter is
shipped, factory settings
allow external signal operations. For PU operation only
set
parameter
79
to
2.
Common
use of
external end
PU
oparatlon
Inverter
I I
FR
-2024
El
Start
switch
When using both operation
modes, setting is as follows:
I
Ex;;d
I
Exteel
I
PU
1
Note: Selection of operation
External
mode A or 0 is made by
setting parameter number
79.
Note:
The
parameter
unit
is
abbreviated
as
'PU'.
-14-
I
Permissive ambient temperature:-1 0 to
+5OoC
Location with explosive gases.
Measuring points
of
the ambient temperature.
/
0
.
/
/
/
/
/
/
/
10
mm
(112
or more
tTv
Q9
Measuring point
On surface of flammable material such as
wood.
or more
0
0
0
0
0
0
0
/
-0
10
mm
(112
inch)
or
more
inchc-
I
,oo
mm
(4
inch)
’
Show Inverter outline
-
16-
6.
WIRING
Wlrlng
When wiring the inverter, pay attention
to
the following points
so
as
to
avoid miswiring
or
misuse.
-
Wiring
(1)
Do
not connect power supply to the output terminals (u,v,w), because such miswiring causes dam-
aae to the inverter.
(2)
Connect nothing across terminals P and
PR
except
the discharging resistor for increased braking
(option). Never short-circuit these terminals.
(3)
Use sleeved, shoulderless terminals for the terminals for power supply and motor.
(4)
Common terminals
SD,
5,
and
SE
on the control circuit terminal block are insulated from each
other.
Do
not
ground
these
termlnals.
(5)
Use shielded or twisted cables for wires connecting the control circuit terminals, and keep suffi-
cient distance from the main or high voltage circuits (e.g.,
200
V
relay sequence circuit).
(6)
When wiring, temporarily cover the vents on top of the inverter,
to
prevent pieces of wire from en-
tering the inverter.
(7)
When doing work such as rearrangement
of
wiring after operating the inverter, make sure that the
power indicator lamp is extinguished and at least two minutes has elapsed before working on the
inverter.
-
17-
h
-
Check the Following Design Details
Interlock
(1)
In addition
to
paying attention
to
miswiring,
check the commercial power source selector
circuit shown In the figure on the right.
If
unde-
sirable application
of
power voltage occurs
aged. Ensure electrical and mechanical interlock of MC
1
and
2.
(2)
At
power failure, retaining the start signal (start switch)
ON
automatically starts the inverter when
Power
supply
W
through such a circuit, the inverter will be dam-
Undesirable power
(3)
Input signals
to
the control circuit are at
low
level.
If
these signals are input through contacts, use
two units of contact for at low level signals or use twin contacts in order
to
prevent defective con-
tacting.
(4)
Do
not apply a voltage
to
contact input terminals (e.g.,
STF)
of
the control circuit.
(5)
Do not apply voltage directly
to
the alarm output terminals (B,C) without a relay coil or lamp.
(Continued on next page)
-18-
h
(6)
If
you connect an open collector output such
as a sequencer directly
to
the inverter input
r---.-l
ProtectivT--;-q
terminal, make sure
that
undesirable current
diode
,
n
may not be generated.
e
Measures
(1)
Insert a diode for preventing undesirable
coupler
current.
(2)
Use an independent output unit.
(example:
AY40A,
etc.
)
uv
MELSEC
L..,..
Sequencer
MELSEC-A
Inverter
-19-
Wlrlng
of
Power
Supply
and
Motor
Terminal
block
'
Power supply
The Dower
su~~lv
must be connected
to
R.
S.
and T.
Never connect'it-to
U,
V,
and W, or the inverter will be
me sequence, is not important.)
Connect the motor to
U,
V,
and W.
With wires connected as shown in the above illustration, turning on the forward rotation switch (signal) will
rotate the motor counterclockwise viewed from the
loading shaft side.
Discharge resistor for
brake
(option)
Notes:
1.
Terminal block
Terminal arrangement
.....
as shown on the previous page.
Screw size
.....
M3.5 screws (FR-Z024-0.1 K to
1.5
K),
M4 screw (FR-Z024-2.2
K,
3.7
K)
Terminal specification
.....
see description of terminal specification (page 120).
2.
Using wire
size
See Selection
of
Peripheral Devices (page 133).
3. The shape
of
terminal block differs according to inverter capacity.
4. Motor overload protection must be provided in accordance with the National Electrical Code.
5.
This drive is not intended to provide overspeed protection.
-21
-
_~_
~-
Wlrlng for Control Clrcult
Frequency meter
This resistor
is
not
required
when meter
is
calibrated
with the parameter unit
Parameter C1
1K
2W
-Frequency reference
Frequency reference
ICalibration tentlometer pol potentiometer
Alarm output
(Ib
contact)
Multi.
Terminal
t
t
I I
i
I
VI
B
c
FM
SD
io
2
5
4
SD
SD
block
SE
RUN
RL
RM
RH
STF STR
MRS
RES
I
I
...
I
I1
I
11.1
Operation
status
output
(RUN: in operation)
(SU: up-to-frequency)
(FU: Frequency detection)
(See
page
93
and
94.)
.speed selection (low speed) or selection
f
t t
t
f
t
t
Reset
of
the
external thermai relay input
(See
page
80
and
91.)
Output shutoff or selection of second
acceleration /deceleration
(See
page
81.)
Start reverse rotation
'j
LL
Multi-speed selection (middle speed) or
se-
lection of the current input
(See
page
91
and
92.)
Multi-speed selection (high speed)
Start forward rotation
-22-
Notes:
1.
Terminal block
Terminal arrangement
.....
as shown in the above illustration (two-row).
Screw
size
.....
M3
screws
controlled via the parameter unit.
2.
Input and output specifications for terminals marked with an asterisk
"I
may be
3.
Three terminals named
SD
are connected in the inverter.
-
23
-
FOR
USE
WITH
SINGLE-PHASE POWER SUPPLY
When the inverter is used with the single-phase power input, the ripple current
of
the capacitor
Increases as compared to the use with the three-phase power input, raising the temperature
of
the converter and capacitor. Hence, the inverter cannot be used with a rated output single-phase
power supply but may be used with the single-phase power input which is lower in output current
than the three-phase power input.
*
FR-2024 FR-2024 FR-2024 FR-2024 FR-Z024 FR-Z024 FR-Z024
Type
-0.1 K -0.2K -0.4K -0.75K -1.5K -2.2K -3.7K
0.4
0.6
1.5
3
4 5 7
Rated output
current
(A)
Rated output
voltage
Power supply
voltage
Power
supply
capacity
(kVA)
0’4
AC
input
cur-
rent
(A)
Three-phase,
200
to
230VAC, 50/60Hz
Single-phase,
200
to
23OVAC,
50/60Hz
0.8
1.5 2.5 4.5 5.5
9
1.1 2.4 4.5 7.6 11.2 12.9 17.4
-24-
r
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